Insulating Device and Method for Forming Insulating Device

ABSTRACT

An insulating device can include an aperture having a waterproof closure which allows access to the chamber within the insulating device. The closure can help prevent any fluid leakage into and out of the insulating device if the insulating device is overturned or in any configuration other than upright. The closure may also prevent any fluid from permeating into the chamber if the insulating device is exposed to precipitation, other fluid, or submersed under water. This construction results in an insulating chamber that is substantially impervious to water and other liquids when the closure is sealed.

This application is a continuation-in-part of U.S. application Ser. No.15/154,626, filed on May 13, 2016, which is a continuation-in-part ofU.S. application Ser. No. 14/831,641, filed on Aug. 20, 2015, which is adivisional application of U.S. application Ser. No. 14/479,607 filed onSep. 8, 2014, now U.S. Pat. No. 9,139,352, which claims priority to U.S.Application No. 61/937,310 filed on Feb. 7, 2014. This application alsoclaims priority to U.S. Application No. 62/292,024 filed on Feb. 5,2016, U.S. Application No. 62/299,421 filed on Feb. 24, 2016, and U.S.Application No. 62/299,402 filed on Feb. 24, 2016. All of the aboveapplications are incorporated fully herein by reference.

FIELD

The present disclosure relates generally to non-rigid, portable,insulated devices or containers useful for keeping food and beveragescool or warm, and, more particularly, an insulating device with awaterproof closure.

BACKGROUND

Coolers are designed to keep food and beverages at lower temperatures.Containers may be composed of rigid materials such as metal or plasticsor flexible materials such as fabric or foams. Coolers can be designedto promote portability. For example, rigid containers can be designed toincorporate wheels that facilitate ease of transport or coolers can bedesigned in smaller shapes to allow individuals to carry the entiredevice. Non-rigid containers can be provided with straps and/or handlesand may in certain instances be made of lighter weight materials tofacilitate mobility. Non-rigid coolers that maximize portability can bedesigned with an aperture on the top that allows access to the interiorcontents of the cooler. The aperture can also be provided with aclosure.

SUMMARY

This Summary provides an introduction to some general concepts relatingto this invention in a simplified form that are further described belowin the Detailed Description. This Summary is not intended to identifykey features or essential features of the invention.

Aspects of the disclosure herein may relate to insulating devices havingone or more of (1) a waterproof closure (2) an outer shell, (3) an innerliner, (4) an insulating layer floating freely in between the outershell and the inner liner, or (5) a waterproof storage compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing Summary, as well as the following Detailed Description,will be better understood when considered in conjunction with theaccompanying drawings in which like reference numerals refer to the sameor similar elements in all of the various views in which that referencenumber appears.

FIG. 1A shows a left front perspective view of an example insulatingdevice in accordance with an aspect of the disclosure;

FIG. 1B shows a frontside perspective view of the example insulatingdevice of FIG. 1A without the shoulder strap;

FIG. 2 shows a backside perspective view of the example insulatingdevice of FIG. 1A without the shoulder strap;

FIG. 3A shows a top perspective view of the example insulating device ofFIG. 1A without the shoulder strap;

FIG. 3B shows a top view of a portion of the example insulating deviceof FIG. 1A;

FIG. 3C shows a portion of an alternate top perspective view of theexample insulating device of FIG. 1A;

FIG. 4 shows a bottom perspective view of the example insulating deviceof FIG. 1A;

FIG. 5A illustrates a schematic of a cross-sectional view of the exampleinsulating device of FIG. 1A;

FIG. 5B illustrates another schematic of an enlarged portion of across-sectional view of the example insulating device of FIG. 1A;

FIG. 6 illustrates an exemplary process flow diagram for forming aninsulating device;

FIGS. 7A-7J illustrate exemplary methods of forming an insulatingdevice;

FIGS. 8A and 8B depict perspective views of an alternative exampleinsulating device.

FIG. 9 depicts a portion of an exemplary closure and an example testmethod for determining if an insulating device maintains the contentstherein.

FIG. 10 depicts an example test for determining the strength of aninsulating device.

FIG. 11 shows a front view of another exemplary insulating device.

FIG. 12 shows a side view of the exemplary insulating device of FIG. 11.

FIG. 13 shows a front perspective view of the exemplary insulatingdevice in an alternate configuration.

FIG. 14A shows a side and cross-sectional view of the exemplaryinsulating device of FIG. 11.

FIG. 14B shows an enlarged section of FIG. 14A.

FIG. 15 shows a schematic exploded view of an exemplary insulation layerfor the example insulating device of FIG. 11.

FIG. 16A shows a portion of another example insulating device.

FIG. 16B shows a side view of the example insulating device of FIG. 16A.

FIG. 17 shows a perspective view of another example insulating device.

FIG. 18 shows a front view of the insulating device of FIG. 17.

FIG. 19 shows a rear view of the insulating device of FIG. 17

FIG. 20 shows a side view of the insulating device of FIG. 17.

FIG. 21 shows a cross-sectional view of the insulating device of FIG.17.

FIG. 22 shows a schematic exploded view of an exemplary insulation layerfor the example insulating device of FIG. 17.

FIG. 22A shows a front view of an exemplary insulation layer for theexample insulating device of FIG. 17.

FIG. 23 illustrates an exemplary testing method.

FIG. 24 shows a front view of an example insulating device in accordancewith an aspect of the disclosure;

FIG. 25 shows a side view of the example insulating device of FIG. 24.

FIG. 26 shows a rear view of the example insulating device of FIG. 24.

FIG. 27 shows a top view of the example insulating device of FIG. 24.

FIG. 28 shows a bottom view of the example insulating device of FIG. 24.

FIG. 29A shows a cross-sectional view of the example insulating deviceof FIG. 24.

FIG. 29B shows a portion of a cross-sectional view of the exampleinsulating device of FIG. 24.

FIG. 30 shows an isometric view of an exemplary insulation layer of theexample insulating device of FIG. 24.

FIG. 31 shows an alternative embodiment for an inner liner of aninsulating device.

FIG. 32 shows the insulating device of FIG. 24 in the opened position.

FIG. 32A shows an example manufacturing method for forming an insulatingdevice.

FIG. 33 shows an example method of securing a handle to an insulatingdevice.

FIG. 34 illustrates an exemplary testing method.

FIG. 35A shows a front view of another exemplary insulating device.

FIG. 35B shows a side view of the exemplary insulating device of FIG.35A.

FIG. 35C shows a rear view of the exemplary insulating device of FIG.35A.

FIG. 35D shows a top view of the exemplary insulating device of FIG.35A.

FIG. 35E shows a bottom view of the exemplary insulating device of FIG.35A.

FIG. 35F shows a cross-sectional view of the exemplary insulating deviceof 35A.

FIG. 36A shows a partial cross-sectional view of an exemplary lid.

FIG. 36B shows a transparent top view of the exemplary lid of FIG. 36A.

DETAILED DESCRIPTION

In the following description of the various examples and components ofthis disclosure, reference is made to the accompanying drawings, whichform a part hereof, and in which are shown by way of illustrationvarious example structures and environments in which aspects of thedisclosure may be practiced. It is to be understood that otherstructures and environments may be utilized and that structural andfunctional modifications may be made from the specifically describedstructures and methods without departing from the scope of the presentdisclosure.

Also, while the terms “frontside,” “backside,” “top,” “base,” “bottom,”“side,” “forward,” and “rearward” and the like may be used in thisspecification to describe various example features and elements, theseterms are used herein as a matter of convenience, e.g., based on theexample orientations shown in the figures and/or the orientations intypical use. Nothing in this specification should be construed asrequiring a specific three dimensional or spatial orientation ofstructures in order to fall within the scope of the claims.

FIGS. 1-4 depict an exemplary insulating device 10 that can beconfigured to keep desired contents stored cool or warm for an extendedperiod of time. The insulating device can generally include an outershell 501, a closure 301, an insulating layer 502, and an inner liner500. As shown in FIG. 3C, the inner liner 500 forms a chamber orreceptacle 504 for receiving the desired contents therein. As shown inFIG. 1A, various handles, straps, and webs (e.g. 210, 212, 218, 224) canalso be included on the insulating device 10 for carrying, holding, orsecuring the insulating device 10.

The insulating device 10 can be configured to keep desired contentsstored in the receptacle 504 cool or warm for an extended period oftime. In one example, the insulating device 10 can also be designed tomaintain water inside the inner chamber or receptacle 504, and theinsulating device 10 can be configured to be water “resistant” from theoutside in. In other words, the insulating device 10 can be formed“water tight” inside the inner liner 500, and water cannot leak into theinner liner 500 from the outside or out from the inside of the innerliner 500 when the closure 301 is in the closed position.

FIG. 4 depicts a bottom view of the insulating device 10. As shown inFIG. 4, the insulating device 10 may include a base 215 and a basesupport ridge 400. The base support ridge 400 can provide structuralintegrity and support to the insulating device 10 when the insulatingdevice 10 is placed onto a surface.

In one example, as shown in FIGS. 3A and 4, the top of the outer shell501 has a first perimeter circumference (T_(cir)) and the bottom of theouter shell 501 has a second perimeter circumference or a base perimeter401 (B_(cir)). The circumference of the top of the outer shell 501 canbe equal to the circumference on the bottom when folded into a cylinder,and B_(cir) can be equal to T_(cir). In one example, the firstcircumference and the second circumference can both have an oval shapeto form an elongated or elliptical cylinder. In one example, the topouter layer 501 a can have a length of 23.5 inches and a width of 5.5inches. Therefore, the length to width ratio of the top outer layer 501a can be approximately 4.3. Additionally, the base 215 can have a lengthof 20.0 inches and a width of 12.25 inches. Therefore, the length towidth ratio of the base 215 is approximately 1.6. In this example, thelength to width ratio of the upper wall can be greater than the lengthto width ratio of the base.

In one example, as shown in FIG. 5A, the inner layer or inner liner 500can be formed of a top inner liner portion or first inner liner portion500 a, an inner layer mid portion or second portion 500 b, and an innerlayer bottom portion 500 c. The top inner liner portion 500 a, the innerlayer mid portion 500 b, and the inner layer bottom portion 500 c aresecured together, by for example welding, to form the chamber 504. Thechamber 504 can be a “dry bag,” or vessel for storing contents. In oneexample, after the top inner liner portion 500 a, the inner layer midportion 500 b, and the inner layer bottom portion 500 c are secured orjoined together, a tape, such as a TPU tape can be placed over the seamsjoining the sections of the chamber 504. The inner liner 500 can, thus,either maintain liquid in the chamber 504 of the insulating device 10 orprevent liquid contents from entering into the chamber 504 of theinsulating device 10. In one example, as will be described in furtherdetail below, the inner liner 500 can be suspended in the insulatingdevice 10 by only the closure 301.

The insulating layer 502 can be located between the inner liner 500 andthe outer shell 501, and can be formed as an insulator to assist inmaintaining the internal temperature of the receptacle 504. In oneexample, the insulating layer 502 can be a free floating layer that isnot attached directly to the outer shell 501 or the inner liner 500. Theinsulating layer 502 can be formed of a first portion 502 a and a secondportion or base portion 502 b. The first portion 502 a and the secondportion 502 b can be formed of an insulating foam material as will bedescribed in further detail below.

The first portion 502 a can have a rectangular shape that maintains itsform when folded into a cylinder and placed in between the inner liner500 and the outer shell 501 and when encased from above by the outershell 501. The insulating layer 502 maintains its shape which results inthe basic oval-cylindrical shape of the insulating device 10. Therefore,similar to the outer shell 501, the top of the insulating layer 502 hasa first perimeter circumference, and the bottom of the insulating layer502 has a second perimeter circumference. The first perimetercircumference of the insulating layer 502 can be equal to the secondperimeter circumference of the insulating layer 502.

The base portion 502 b can be included to provide additional insulationalong the insulating device 10 at base 215. The base portion 502 b canbe formed as an oval shape to close off a lower opening 506 formed bythe cylindrical shape of the insulating layer 502.

Additionally, the bottom portion of the insulating device 10 can includean additional base support layer 505, which adds to the insulation andthe structural integrity of the insulating device 10. The base supportlayer 505 may also provide additional protection around the bottom ofthe insulating device 10. In one example, the base support layer 505 canbe formed from EVA foam. The base support layer 505 may include acertain design such as a logo or name that can be molded or embosseddirectly into the material. The base support ridge 400, which providesstructural integrity and support to the insulating device 10 can also bemolded or embossed directly into the base support layer 505. In oneexample, the base support layer 505 and the base portion 502 b can bedetached for ease of assembly.

The outer shell 501 can be formed of a top outer layer portion or firstshell portion 501 a, an outer layer or second outer shell portion 501 b,and a bottom or third shell portion 501 c. The outer shell 501 providesa covering for the insulating device 10. In one example, the insulatinglayer 502 can be suspended freely within the outer shell 501. However,it is contemplated that any of the layers could be secured or formed asa one-piece integral structure. The outer shell 501 can be configured tosupport one or more optional handles or straps (e.g. 210, 212, 218). Inthis regard, the outer shell 501 can also include multiple reinforcementareas or patches 220 that are configured to assist in structurallysupporting the optional handles or straps (e.g. 210, 212, 218). Thehandles or straps (e.g. 210, 212, 218) and other attachments can bestitched using threads 222, however these threads 222 do not, in oneexample, extend through the outer shell 501 into the insulating layer502. Rather, the threads are sewn to the patches 220, and the patches220 can be RF welded to the outer shell 501 or by any other methoddisclosed herein.

As shown in FIG. 5A, the first outer shell portion 501 a may be attachedto the second shell portion 501 b by stitching 510. However, the firstouter shell portion 501 a can be attached to the second shell portion501 b using any known method, e.g., polymer welding, stitching, or otheradhesive around the entire perimeter of the second shell portion 501 b.

Additionally, in one example, the base support layer 505, which can beformed from EVA foam, can be secured to bottom or third shell portion501 c by lamination. The second shell portion 501 b can be secured tothe third shell portion 501 c and the base support layer 505 by polymerwelding (e.g. RF welding), stitching, or adhesives.

The insulating device 10 can include two carry handles 210 that areconnected to the frontside 216 of the insulating device 10 and thebackside 217 of the insulating device 10. In one particular example, ashoulder strap 218 can be attached via plastic or metal clip to the ring214 attached to side handles 212 to facilitate carrying insulatingdevice 10 over the shoulder. The insulating device 10 may also includeside handles 212 on each end of the cooler. The side handles 212 providethe user with another option for grasping and carrying the insulatingdevice.

Carry handles 210 may also form a slot for receiving rings 214 near thebottom of the attachment point of the carry handles to the insulatingdevice 10. The rings 214 can be secured to the carry handles 210 and theattachment points 213 by stitching, adhesive, or polymer welding and canbe used to help secure or tie down the insulating device 10 to anotherstructure such as a vehicle, vessel, camping equipment, and the like orvarious objects such as keys, water bottle bottles, additional straps,bottle openers, tools, other personal items, and the like.

Additionally, as shown in FIG. 2, webbing formed as loops 224 can besewn onto the straps forming the handles 210 on the back of theinsulating device 10. The loops 224 can be used to attach items (e.g.,carabineers, dry bags) to the insulating device 10. The side handles 212can also provide the user with another option for securing theinsulating device 10 to a structure.

In one example, the carry handles 210, side handles 212, shoulder strap218 and attachment points 213 can be constructed of nylon webbing. Othermaterials may include polypropylene, neoprene, polyester, Dyneema,Kevlar, cotton fabric, leather, plastics, rubber, or rope. The carryhandles 210 and side handles 212 can be attached to the outer shell bystitching, adhesive, or polymer welding.

The shoulder strap 218 can be attached to the insulating device 10 atattachment points 213. The attachment points 213 can be straps that alsoform a slot for receiving rings 214. The rings 214 can provide for theattachment of the shoulder strap 218.

In one example, the rings 214 can be Acetal D-rings. Rings 214 in can beplastic, metal, ceramic, glass, alloy, polypropylene, neoprene,polyester, Dyneema, and Kevlar, cotton fabric, leather, plastics,rubber, or rope. Rings 214 can include other shapes, sizes, andconfigurations other than a “D” shape. Examples include round, square,rectangular, triangular, or rings with multiple attachment points.Additionally, pockets or other storage spaces can be attached to theoutside of the insulating device 10 in addition to the carry handles 210and side handles 212.

In one example, the closure 301 can be substantially waterproof or abarrier to prevent liquid contents from either entering or exiting theinsulating device. Additionally, the closure 301 can be impervious toliquid such that insulating device 10 liquid penetration is prevented atany orientation of the insulating device 10. Also maintaining theclosure 301 in flat plane can assist in providing a water tight seal.

FIGS. 3A-3C depicts top views of the insulating device 10, and depictsthe top outer layer or the first outer shell portion 501 a and theclosure 301. The top outer layer 501 a depicted in FIG. 3A can besecured to the closure 301. In one example, the closure 301 can be awaterproof zipper assembly and can be watertight up to 7 psi aboveatmospheric pressure during testing with compressed air. However, inother examples, the water tightness of the closure 301 can be from 5 psito 9 psi above atmospheric pressure and in other examples, the watertightness of the closure 301 can be from 2 psi to 14 psi aboveatmospheric pressure. The waterproof zipper assembly can include aslider body 303 and pull-tab 302. FIG. 3B shows a magnified view of theclosure 301 that includes bottom stop 304 and teeth or a chain 305. Inone particular example, the waterproof zipper assembly can beconstructed with plastic or other non-metallic teeth 305 to preventinjury when retrieving food or beverages from the inner chamber 504.

As shown in FIG. 3C, the closure 301 is open or unzipped and an aperture512 formed in the outer shell 501 and the inner liner 500 is open andreveals the inner liner 500 and the inner chamber 504. It iscontemplated that the closure or seal 301 can include various sealingdevices in addition to the depicted waterproof zipper assembly in FIGS.3A-3C. For example, Velcro, snaps, buckles, zippers, excess materialthat is folded multiple times to form a seal such as a roll-down seal,seals, metal or plastic clamps and combinations thereof could be used toseal the inner liner 500 and the outer shell 501.

FIGS. 8A and 8B depict another exemplary insulating device 1010, whichhas similar features and functions as the example discussed above inrelation to FIGS. 1A-5B in which like reference numerals refer to thesame or similar elements. However, in this example, a loop patch 1015can be provided on the front of the bag. The loop patch 1015 can beconfigured to receive many types of items or a corresponding group ofhooks, which can be placed onto the surface anywhere on various items,such as fishing lures, keys, bottle openers, card holders, tools, otherpersonal items, and the like. The loop patch 1015 can include a logo,company name, personalization, or other customization. The loop patch1015 can be formed of by needle loops and can have a high cycle life ofover 10,000 closures. In addition, the loop patch can be washable and UVresistant to prevent discoloration. The loop patch can be selected basedon a desired sheer and peel strength depending on the types of materialsthat are to be secured to the insulating device 1010.

In the example shown in FIGS. 8A and 8B, additionally, a strip 1013 ofmaterial can be provided along the bottom of the bag, which can provideadditional strength and reinforcement to the outer shell 1501, and mayenhance the aesthesis of the insulating device 1010.

Example methods of forming the insulating device 10 will now bedescribed. A general overview of an exemplary assembly process of theinsulating device 10 is depicted schematically in FIG. 6. The varioussteps, however, need not necessarily be performed in the orderdescribed. As shown in step 602 first the portions used to form theinner liner 500, the outer shell 501, and the insulating layer 502 canbe formed or cut to size. In step 604, a top cap assembly 300 can beassembled to the closure 301. In step 606, the inner liner 500 can beformed, and in step 608, the top cap assembly 300 can be welded to theinner liner 500. In step 610, the outer shell 501 can be formed. In step612, the insulation layer 502 can be assembled, and in step 616, theinsulation layer 502 can be placed into the inner liner. Finally, instep 618, the top cap assembly 300 can be secured to the outer shell501.

Referring to step 602, as shown in FIGS. 7A and 7B, inner liner topportions or first inner liner portions 500 a and top outer layer 501 athat form the top cap assembly 300 can be formed or cut to size. FIG. 7Cshows a second portion or base portion 502 b of the insulating layer 502being cut or formed to size from stock foam. In this example, the baseportion 502 b is cut from the stock foam 530, by cutting tool 700. Inone example, the cutting tool 700 can be formed in the shape of the baseportion 502 b.

Referring now to step 604 and FIG. 7D, the top outer layer 501 a and thetop inner liner portion 500 a can be secured to the closure 301 to formthe top cap assembly 300, and the top outer layer 501 a and the topinner liner portion 500 a can be secured to the closure 301 in a flat,horizontal plane. Referring to FIGS. 5A-5B the top outer layer 501 a canbe attached by polymer welding or adhesive to closure 301. In particularas shown schematically in FIG. 5B, the closure 301 can be provided witha first flange 301 a and a second flange 301 b, which can formwaterproof zipper tape 306. The top outer layer 501 a can be attacheddirectly to the top surfaces of the first flange 301 a and the secondflange 301 b of the closure 301. In one example, the first flange 301 aand the second flange 301 b, can be RF welded to the underside of thetop outer layer 501 a. In another example, as shown in FIG. 7E, the topinner liner portion 500 a can be provided with tabs 515. Tabs 515 canassist in the assembly process to keep the outer strips of the top innerliner portion 500 a in place during assembly and can be removed afterthe top cap assembly 300 is formed.

In one example, the top inner liner portion 500 a can be attached to thestructure of the insulating device 10 as shown schematically in FIG. 5B.In particular, the top inner liner portion 500 a can be attached to thebottom of the closure 301. For example, as shown in FIG. 5B, and a firstend 540 a and a second end 540 b of the top inner liner portion 500 acan be attached to undersides of the first flange 301 a and the secondflange 301 b. The top inner liner portion 500 a and the top outer layer501 a can be attached to the closure 301 by polymer welding or adhesive.Polymer welding includes both external and internal methods. External orthermal methods can include hot gas welding, hot wedge welding, hotplate welding, infrared welding and laser welding. Internal methods mayinclude mechanical and electromagnetical welds. Mechanical methods mayinclude spine welding, stir welding, vibration welding, and ultrasonicwelding. Electromagnetical methods may include resistance, implant,electrofusion welding, induction welding, dielectric welding, RF (RadioFrequency) welding, and microwave welding. The welding can be conductedin a flat or horizontal plane to maximize the effectiveness of thepolymer welding to the construction materials. As a result, a ruggedwatertight seam can be created that prevents water or fluids fromescaping from or into the inner chamber 504.

In a particular example, the polymer welding technique to connect thetop inner liner portion 500 a to the bottom of the closure 301 caninclude RF welding. The RF welding technique provides a waterproof seamthat prevents water or any other fluid from penetrating the seam atpressure up to 7 psi above atmospheric pressure. The insulating device10, therefore, can be inverted or submerged in water and leakage isprevented both into and out of the internal chamber 504 formed by innerliner 500. In one example, the insulating device 10 can be submergedunder water to a depth of about 16 feet before water leakage occurs.However, it is contemplated that this depth could range from about 11feet to 21 feet or 5 feet to 32 feet before any leakage occurs.

Next referring to step 606 and FIG. 7F, the inner layer mid-portion 500b can be formed by RF welding. As shown in FIG. 7F, the inner layermid-portion 500 b can be formed of a rectangular sheet of material. Theinner layer mid-portion 500 b can also be secured to the inner layerbottom portion 500 c in a subsequent step not shown.

Referring to step 608 and FIGS. 7G and 7H, the inner layer mid portion500 b and the inner layer bottom portion 500 c can be secured to the topcap assembly 300 using an RF welding operation.

Referring to step 610, the second shell portion 501 b and the thirdshell portion 501 c, which supports the base support layer 505, can beRF welded to construct the outer shell 501 for the insulating device 10.In one example, as shown schematically in FIG. 5A, the top outer layer501 a can be sewed to the perimeter of the second shell portion 501 b toform the outer shell 501 of the insulating device. A fabric binding canbe used to cover the stitched seam edges of the second shell portion 501b and the top outer layer 501 a. This assists in closing or joining theouter shell 501 around the insulating layer 502.

Referring to step 612 and FIG. 71, the insulating layer 502 can beconstructed. In one example the first portion 502 a of the insulatinglayer 502 can be formed into a rectangular shape and can be secured atthe smaller sides of the rectangular shape using double sided tape toform the cylindrical shape. The second portion or base portion 502 b canbe formed into an oval shape that can have a smaller circumference thanthe circumference of the cylindrical shape of the first portion 502 a.The second portion 502 b can be secured to the first portion 502 a alsousing a double-sided tape to form the insulating layer 502. In oneexample, double sided tape can be placed either around the innerperimeter of the first portion 502 a cylinder or around the outerperimeter of the base portion 502 b, and the base portion 502 b can beadhered to the first portion 502 a. Other methods of securing the baseportion 502 b to the first portion 502 a to form the insulating layer502 are contemplated, such adhesives or polymer welding.

Referring to step 614, the assembled insulating layer 502 can be placedinto the outer shell 501. In step 616, the formed inner liner 500 andtop cap assembly 300 can be placed into the insulating layer 502.

Finally in step 618 the top cap assembly 300 can be sewed to the outershell 501 to form seams 520 as depicted schematically in FIG. 5A. Inthis way, neither the inner liner 500 nor the outer shell 501 need to bebound to the insulating layer 502. Also the inner liner 500 is onlyconnected to the closure 301 and the closure 301 holds the inner linerand the outer shell 501 together, which results in a simplermanufacturing process. After sewing the top cap assembly 300 to theouter shell 501, a fabric binding is added to cover the raw edgesadjacent the seams 520. Thus, the top seams 520 can be the only primaryseams on the insulating device 10 that are created by stitching.

In one particular example, the inner liner 500 and the outer shell 501can be constructed from double laminated TPU nylon fabric. Nylon fabriccan be used as a base material for the inner liner 500 and the outershell 501 and can be coated with a TPU laminate on each side of thefabric. The TPU nylon fabric used in one particular example is 0.6millimeters thick, is waterproof, and has an antimicrobial additive thatmeets all Food and Drug Administration requirements. However, it iscontemplated that the fabrics used to construct the insulating deviceincorporate antimicrobial materials to create a mildew-free environmentthat is food contact surface safe. In one specific example, the nyloncan be 840d nylon with TPU. Alternative materials used to manufacturethe inner shell or chamber 504 and outer shell 501 include PVC, TPUcoated nylon, coated fabrics, and other weldable and waterproof fabrics.

A closed cell foam can be used to form the insulating layer 502 that issituated in between the inner liner 500 and the outer shell 501. In oneexample, the insulating layer 502 is 1.0 inches thick. In one example,the insulating layer 502 can be formed of NBR/PVC blend or any othersuitable blend. The thermal conductivity of an example insulating layer502 can be in the range of 0.16−0.32 BTU.in/(hr·sqft·° F.), and thedensity of the insulating layer 502 can be in the range of 0.9 to 5lbs/ft³. In one example, the thermal conductivity of the insulatinglayer 502 can be in the range of 0.25 BTU.in/(hr·sqft·° F.), and thedensity of the insulating layer 502 can be 3.5 lbs/ft³.

The foam base can be manufactured from an NBR/PVC blend or any othersuitable blend. In addition to the base portion 502 b of the insulatinglayer 502, the insulating device 10 may also include an outer basesupport layer 505 constructed of foam, plastic, metal or other material.In one example, the base portion 502 b can be detached from the basesupport layer. In one example, the base portion 502 b is 1.5 inchesthick. Additionally as shown in FIG. 5A, the EVA foam base support layer505 can be 0.2 inches thick. Although the base support layer 505 islaminated to the base outer layer or third shell portion 501 c, in analternative example, the base support layer 505 can be attached to thebottom of the base portion 502 b by co-molding, polymer welding,adhesive, or any known methods.

A heat gain test was conducted on the exemplary insulating device 10.The purpose of a heat gain test is to determine how long the insulatingdevice can keep temperature below 50° F. at an ambient of 106° F.±4 withthe amount of ice based on its internal capacity.

The procedure is as follows:

1. Turn on the oven and set to 106° F.±4. Allow the oven to stabilizefor at least one hour.

2. Turn on the chart recorder. The recorder shall have threeJ-thermocouples connected to it to chart the following temperatures: (1)Test unit, (2) Oven, and (3) Room ambient.

3. Stabilize the test unit by filling it to half its capacity with icewater, and allowing it to sit for 5 minutes at room temperature (72°F.±2).

4. After 5 minutes, pour out the contents, and immediately connect theJ-thermocouple end to the inside bottom center of the unit. Thethermocouple wire end must be flush to the inside bottom surface andsecured with an adhesive masking tape.

5. Pour the correct amount of ice ensuring the thermocouple wire is notmoved. Amount of ice is based on 4 lbs. per cubic feet of the internalcapacity of the unit.

6. Close the lid and position the test unit inside the oven.

7. Close the oven making sure the thermocouple wires are functioning.

8. Mark the start of the chart recorder.

Apparatus: 1. Oven. 2. Ice. 3. Chart Recorder. 4. J-Thermocouples (3).Results: 1. Cold Retention Time: Elapsed time from <32° F. to 50° F. indecimal hours. 2. Heat Gain Rate (° F./Hr): (50° F.−32° F.)±ElapsedTime=18° F.±Elapsed Time

In one test of the example insulating device, the heat gain rate equaled1.4 degF/hr assuming 26.5 quarts capacity and used 3.542 lbs of ice forthe test.

The ability of the insulating device 10 to withstand interior leaks canalso be tested to see how well the insulating device maintains thecontents stored in the storage compartment or receptacle 504. In oneexample test, the insulating device 10 can be filled with a liquid, suchas water, and then can be inverted for a predetermined time period totest for any moisture leaks. In this example, the insulating device 10is filled with a liquid until approximately half of a volume of thereceptacle 504 is filled, e.g. 3 gallons of water, and the closure 301is then closed fully to ensure that the slider body 303 is completelysealed into the horseshoe-shaped portion 308. The entire insulatingdevice 10 is then inverted and held inverted for a time period of 30minutes. The insulating device 10 is then reviewed for any leaks.

The insulating device 10 can be configured to withstand being heldinverted for 30 minutes without any water escaping or leaving thereceptacle 504. In alternative examples, the insulating device can beconfigured to withstand being held inverted for 15 minutes to 120minutes without any water escaping or leaving the receptacle 504. Toperform this test, it may be helpful to lubricate the closure to ensurethat the closure is adequately sealed. For example, as shown in FIG. 9,a horseshoe-shaped portion 308 of the closure 301 is provided withlubricant 309.

The strength and durability of the fabric forming the outer shell 501,inner liner 500 and the insulating layer 502 of the insulating device 10may also be tested. In one example, the test can be devised as apuncture test. In particular, this test can be designed as an ASTMD751-06 Sec. 22-25 screwdriver puncture test. In one example, theinsulating device 10 can withstand 35 lbs to 100 lbs of puncture force.

The handle strength and durability of the insulating device 10 can alsobe tested. One such example test is depicted in FIG. 10. As depicted inFIG. 10, the closure 310 can be fully closed, one of the carry handles210 can hooked to an overhead crane 600, and the opposite carry handle210 is hooked to a platform 650, which can hold weight. In one example,the platform 650 can be configured to hold 200 lbs. of weight. Duringthe test, the crane 600 is slowly raised, which suspends the insulatingdevice 10 in a position where the bottom plane of the insulating device10 is perpendicular with the floor. In one example, the insulatingdevice 10 can be configured to hold 200 lbs. of weight for a minimum of3 minutes without showing any signs of failure. In alternative examples,the insulating device can be configured to hold 100 lbs. to 300 lbs. ofweight for 1 to 10 minutes without showing signs of failure.

FIGS. 11-15 show another example insulating device 2010. The exampleinsulating device 2010 can be of a similar construction to the aboveexamples, where like reference numerals represent like features havingsimilar functionality. However, the example insulating device 2010 canalso include a fold-down flap or portion 2307 to assist in insulatingthe closure 2311 of the insulating device 2010. Specifically, theclosure 2311, which can be a zipper in accordance with the otherexamples discussed herein, can be included on a fold-down flap orportion 2307 and can be front facing in that it is located on a frontsurface or wall of the insulating device 2010. The front facing closure2311, can allow for additional user access to the insulating device2010, and the fold-down flap or portion 2307 can help to provideadditional insulation at the closure 2311. In this example, when thefold-down flap 2307 is in the extended position and the closure 2311 isopen or unsealed, the contents in the insulating device 2010 maintainthe closure 2311 in the open position for better access of the contentsof the insulating device 2010. This may assist the user to be able tomore easily access the contents of the insulating device 2010. Also asshown in FIG. 11, when the fold-down flap 2307 is in the extendedposition, the insulating device 2010 can approximate a trapezoidal shapefor providing an elongated closure at the top of the insulating device2010.

As shown in the side and cross-sectional views, i.e., FIGS. 12 and 14A,the insulating device 2010 can approximate a pentagon, when thefold-down flap 2307 of the insulating device 2010 is in an extendedposition. This general shape may provide for an insulating device 2010that may be easily shipped in that several insulating devices can be fitinto a shipping container. Nevertheless, other shapes and configurationsare contemplated e.g., square, rectangular, triangular, conical, curved,and frusto-shapes which may provide an extended closure at the top ofthe insulating device 2010 and that can be easily packaged.

Like in the above examples, the insulating device 2010 may include anouter shell 2501, an inner liner 2500 forming a storage compartment, areceptacle, or inner chamber 2504 and an insulating layer 2502positioned in between the outer shell 2501 and the inner liner 2500. Theinsulating layer 2502 provides insulation for the storage compartment2504. The closure 2311 can be configured to substantially seal anopening 2512, which is located on an angled front facing surface andextends through the outer shell 2501 and the inner liner 2500 to provideaccess to the storage compartment 2504. Also, the closure 2311 caninclude similar features and functionality in accordance with theexamples discussed above. In one example, the closure 2311 can be azipper and can be substantially waterproof so as to resist liquid fromexiting the opening when the insulating device 2010 is in anyorientation. Also, similar to the above examples, the insulating device2010 can be provided with one or more of carry handles 2210, shoulderstraps 2218, webbing loops 2224 formed with threads 2222 by stitchingfor example, rings 2214, and attachment points 2213 which can havesimilar features and functionality as in the examples above.

As shown in FIGS. 11 and 12 and as noted above, the fold-down flap 2307may include the front facing closure 2311 and can be folded over andsecured to a sidewall of the insulating device 2010 to further insulatethe front facing closure 2311. The fold-down flap 2307 of the fasteningmechanism 2301 can include first and second end hooks or clips 2313 a,2313 b. In one example, each of the end clips 2313 a, 2313 b can includea slot 2317 a, 2317 b for being received in corresponding loops 2315 a,2315 b located on the sides or the sidewalls of the insulating device2010. To close the insulating device 2010, the fold-down flap 2307 alongwith the front facing closure 2311 are folded over onto a front face orwall of the insulating device 2010. The fold-down flap 2307 folds overwith and conceals or covers the front facing closure 2311. The fold-downflap 2307 is held into place by the first and second end clips 2313 a,2313 b and maintains the fastening mechanism 2301 in the closedposition. Additionally, when the fold-down portion 2307 is secured tothe sidewalls of the insulating device 2010, the fold-down portion 2307extends at least partly in a substantially horizontal direction, whichorients a carrying handle 2318 in position for a user to grasp forholding and carrying the insulating device 2010. As in the other handlesand straps, the carry handle 2318 can be secured to the outer shell witha reinforcement patch (not shown). The carry handle 2318 can be providedon the rear surface of the insulating device 2010 to oppose the closure2311 on the front facing surface, which can be used by the user to graspduring opening and closing the insulating device 2010 to make it easierfor the user to open and close the closure 2311. The carry handle 2318may also be used for hanging the insulating device 2010, or for carryingthe insulating device 2010; however, other uses are also contemplated.

FIG. 14A shows a cross-sectional side view of the insulating device2010. The insulating device 2010 includes an inner liner 2500, aninsulating layer 2502, and an outer shell 2501. As shown in FIG. 14A,like in the above examples, the insulating layer 2502 can be locatedbetween the inner liner 2500 and the outer shell 2501, and can be formedas a foam insulator to assist in maintaining the internal temperature ofthe receptacle 2504 for storing contents desired to be kept cool orwarm. Also the insulating layer 2502 can be located in between the innerliner 2500 and the outer shell 2501, and can be unattached to either theinner liner 2500 or the outer shell 2501 such that it floats between theinner liner 2500 and the outer shell 2501. In one example, the innerliner 2500 and the outer shell 2501 can be connected at the top portionof the insulating device 2010 such that the insulating layer 2502 canfloat freely within a pocket formed by the inner liner 2500 and theouter shell 2501.

In this example, the inner layer or inner liner 2500 can be formed of afirst inner liner sidewall portion 2500 a and a bottom inner linerportion 2500 b. The first inner liner sidewall portion 2500 a and thebottom inner liner portion 2500 b can be secured together, by forexample welding, to form the chamber 2504. Like in the above example,the chamber 2504 can be a “dry bag,” or vessel for storing contents. Inone example, a tape, such as a TPU tape, can be placed over the seamsjoining the sections of the chamber 2504, after the first inner linersidewall portion 2500 a and the bottom inner liner portion 2500 b aresecured or joined together. The tape seals the seams formed between thefirst inner liner sidewall portion 2500 a and the bottom inner linerportion 2500 b to provide an additional barrier to liquid to preventliquid from either entering or exiting the chamber 2504. The inner liner2500 can, thus, either maintain liquid in the chamber 2504 of theinsulating device 2010 or prevent liquid contents from entering into thechamber 2504 of the insulating device 2010. It is also contemplated,however, that the inner liner 2504 can be formed as an integralone-piece structure that may be secured within the outer shell.

As shown in both FIGS. 14A and 15, the insulating layer 2502 can beformed of a first portion or an upper portion 2502 a, a second portionor base portion 2502 b, and a base support layer 2505. In addition, thefirst portion 2502 a can include a top flap or smaller rectangular shape2502 a 1. When the fold-down flap 2307 is folded onto the top portion ofthe insulating device 2010, the top flap 2502 a 1 of the insulatinglayer together with the remainder of the first portion 2502 a and thebase portion 2502 b surrounds substantially all of the inner chamber2504 with insulation to provide a maximum amount of insulation to theinner chamber 2504 of the insulating device 2010.

When the upper portion 2502 a is rolled flat, the upper portion 2502 aof the insulating layer 2502 generally resembles a “T” shape such thatthe insulating layer defines a first height H₁ and a second height H₂where the first height H₁ is greater than the second height H₂. In thisexample, a majority of the insulating layer can extend to the secondheight H₂, which is less than the first height H₁. Also, the firstportion 2502 a can be formed of two inter-connected rectangular shapes,where the bottom of the first portion 2502 a forms a first largerrectangular shape 2502 a 2 and an upper section of the first portion2502 a forms the top flap 2502 a 1 of the smaller rectangular shape. Itis also contemplated that the first larger rectangular shape 2502 a 2can be formed as a separate piece from the smaller rectangular shape2502 a 1. The first rectangular shape 2502 a 2 can have a firstrectangular width and the second rectangular shape 2502 a 1 can have asecond rectangle perimeter and first rectangular shape 2502 a 2 widthapproximates the second rectangular shape 2502 a 1 perimeter. In oneexample, the smaller rectangular shape 2502 a 1 forms a top flap of theinsulation layer of the upper portion 2502 a, which extends into thefold-down portion 2307.

The first portion 2502 a and the second portion 2502 b can be formed ofan insulating foam material as discussed herein. In one example, thesecond portion 2502 b can be formed of a thicker foam material than thefirst portion 2502 a. For example, the thickness of the second portion2502 b can be formed between 20 mm and 50 mm thick, and, in oneparticular example, can be formed of a 38 mm thick foam, and the firstportion 2502 a can be formed between 15 mm and 30 mm, and, in oneparticular example, can be formed of a 25 mm thick foam. In one example,the foam can be a NBR/PVC blended foam, a PVC free NBR foam, or othereco-friendly type foam.

Also as shown in FIG. 15, a base support layer 2505 adds to theinsulation and the structural integrity of the insulating device 2010 atbase 2215. The base support layer 2505 may also provide additionalprotection around the bottom of the insulating device 2010. In oneexample, the base support layer 2505 can be formed from EVA foam. Thebase support layer 2505 may include a certain design such as a logo orname that can be molded or embossed directly into the material. A basesupport ridge 2400, which provides structural integrity and support tothe insulating device 2010 can also be molded or embossed directly intothe base support layer 2505. In one example, the base support layer 2505and the base portion 2502 b can be detached or unsecured for ease ofassembly in reducing the number of assembly steps. The base portion 2502b can be formed as an oval shape to close off a lower opening 2506formed by the open shape of the upper portion 2502 a.

The bottom of the first portion 2502 a maintains its form when foldedinto an oval-cylindrical shape and placed in between the inner liner2500 and the outer shell 2501. The insulating layer 2502 maintains itsshape which results in the basic oval-cylindrical shape of theinsulating device 2010.

The outer shell 2501 can be formed of an upper sidewall portion 2501 a,a lower sidewall portion 2501 b, and a base portion 2501 c. Each of theupper sidewall portion 2501 a, the lower sidewall portion 2501 b, andthe base portion 2501 c can be secured by stitching. Other securingmethods are also contemplated, such as, using welds or adhesives.

Additionally, the fold-down portion 2307 can be at least partly free offoam to make it easier to close the fastening mechanism 2301. Inparticular, the fold-down portion 2307 can include a first section 2307a and a second section 2307 b. The first section 2307 a can be free ofthe insulation layer 2502 and the second section can include theinsulation layer 2502.

Referring to FIG. 14B, like in the above examples, the closure 2311 canbe mounted on a backing or fabric. In the case of a zipper this can bereferred to as zipper tape 2306. Also, like in the above examples, thezipper tape 2306 can be attached between the inner liner 2500 and theouter shell 2501 and, in particular, the zipper tape 2306 can be securedto the upper sidewall portion 2501 a of the outer shell and the firstinner liner sidewall portion 2500 a. As shown in FIG. 14B, the zippertape 2306, the upper sidewall portion 2501 a of the outer shell, and thefirst inner liner sidewall portion 2500 a can form a stacked arrangementof a sandwich structure where the zipper tape 2306 is located betweenthe upper sidewall portion 2501 a of the outer shell and the first innerliner sidewall portion 2500 a.

The insulating device 2010 can be formed using similar techniques inrelation to the examples as discussed above. For example, the uppersidewall portion 2501 a of the outer shell 2501 can be formed. Also thebase 2215 can be formed separately with the base portion 2502 b of theinsulation layer 2502, the base support layer 2505, the lower sidewallportion 2501 b, and a base portion 2501 c of the outer shell 2501according to the techniques discussed herein. The base 2215 can besecured to the bottom of the upper sidewall portion 2501 a of the outershell 2501 using the techniques discussed herein. The upper portion 2502a of the insulation layer 2502 can be placed within the upper sidewallportion 2501 a of the outer shell 2501. The first inner liner sidewallportion 2500 a and the bottom inner liner portion 2500 b can then besecured to form the inner liner 2500 and chamber 2504. Tape, such as aTPU tape, can be placed over the seams joining the sections of the innerliner 2500 and chamber 2504. The inner liner 2500 can then be placedwithin the insulation layer 2502. The closure 2311 can then be attachedbetween the inner liner sidewall portion 2500 a and the upper sidewallportion 2501 a. At this point in the process the insulating device 2010assembly will have a cylindrical shape with an open top. To close theopen top, the upper ends of the inner liner sidewall portion 2500 a andthe upper sidewall portion 2501 a can then be secured together bywelding or by using any of the techniques discussed herein to form theinsulating device 2010. A binding 2518 can be applied to the top portionof the insulating device 2010 to cover and conceal the seam between theouter shell 2501 and the inner liner 2500. The loop patch (not shown),carry handles 2210, shoulder strap 2218, webbing loops 2224, and rings2214 can be added to the outer shell 2501 by the various techniquesdiscussed herein, after the formation of the outer shell or once theinsulating device 2010 is formed. It is contemplated that the innerliner and the outer liner can be formed by welding, gluing, or stitchingand combinations thereof.

In another example, a magnetic connection can be implemented forsecuring the fold-down portion 2307 to the body of the insulating device2010. As shown in FIGS. 16A and 16B, the insulating device 2010 can beprovided with a magnetic clip 3313, which can be received by acorresponding magnet (not shown) on the sidewall of the insulatingdevice 2010. However, it is also contemplated that the clip and clipreceiving portion on the insulating device 2010 could be one or more ofpermanent magnets, metal strips, or ferromagnetic materials. Inaddition, other methods of securing the fold-down flap 2307 over thefront facing closure 2311 are also contemplated. For example, one ormore of hook and loop, buckle, snap, zipper, detent, spring loadeddetent, button, cams, or threads could be used to secure the fold-downflap 2307 to the sidewall of the insulating device 2010.

FIGS. 17-22 show another exemplary insulating device 4010. The exampleinsulating device 4010 can be of a similar construction to the aboveexamples and, in particular, the example discussed above in relation toFIGS. 11-16B, where like reference numerals represent like featureshaving the same or similar functionality. In this example, theinsulating device 4010 does not include a fold-down flap and can includea different overall shape than the example insulating device 2010.Additionally, the insulating layer 4502 can have a differentconfiguration along with other variations that will be discussed below.Like in the above example, the closure 4311 can be placed on a frontface or wall of the insulating device 4010.

As shown in FIGS. 18 and 19, when viewed from the front and rear, theinsulating device 4010 can generally form a trapezoidal shape, where theinsulating device diverges or tapers upward toward the top of theinsulating device 4010. The trapezoidal shape may provide certaininsulation, user accessibility, and packaging benefits. For example, thetrapezoidal shape can provide an extended period of ice coverage becauseof the additional foam that can be placed between the outer shell 4501and the inner liner 4500 due to the trapezoidal shape.

Additionally, the overall shape of the insulating device 4010 can helpto maintain the insulating device 4010 in the opened position when theclosure 4311 is in the opened position and permits the user to be ableto easily access the contents of the insulating device 4010. Thetrapezoidal shape as discussed herein also allows the closure 4311 to beformed longer relative to the insulating device 4010. Other shapes thatallow for an extended opening at the upper portion of the insulatingdevice 4010 are also contemplated. For example, the upper portion of theinsulating device 4010 could be formed with an extended curvature eitherupward or downward to allow for a larger closure extending across theupper portion of the insulating device 4010. Also as shown in FIG. 20,when viewed from the side, the insulating device 4010 can be formedgenerally conical, tapered or funnel-shaped such that the sides convergeto the top of the insulating device 4010. Also the sides can be formedsubstantially parabolic in shape in certain examples. Therefore, theinsulating device 4010 converges to an apex along the top of theinsulating device 4010 as opposed to an oval shape with the sameperimeter as the bottom of the insulating device 4010.

In certain examples, a trapezoidal shape may also provide for aninsulating device 4010 that may be easily shipped in that severalinsulating devices 4010 can be fit into a shipping container. Forexample, multiple insulating devices 4010 could be arranged in ashipping container in different orientations so as to utilize more spacewithin a shipping container.

In alternative embodiments, when the closure 4311 is in the opened orunsealed position, the contents in the insulating device 4010 maymaintain the closure 4311 in the open position for easier access to thecontents of the insulating device 4010. In this example, the weight ofthe contents can force a lower half of the closure 4311 away from anupper half of the closure 4311 such that the user can better see thecontents of the insulating device 4010 and more easily remove thecontents or add contents to the insulating device 4010.

In this example, the outer shell construction, insulating layer, and theinner liner construction can be similar to that of the embodimentdiscussed above in relation to FIGS. 11-16B, the details of which arenot repeated here. The outer shell 4010 may also include a top portion4316, which is configured to receive the closure 4311 therein. The topportion 4316 can be formed of the same material as the remaining outershell 4501, which in one specific example, can be nylon and specificallyan 840d nylon with TPU.

Similar to the example discussed in relation to FIGS. 11-16B, theinsulating device 4010 can be provided with one or more of carry handles4210, a shoulder strap 4218, webbing loops 4224, which are formed bythreads 4222, rings 4214, and attachment points 4213 which can havesimilar features and functionality as in the examples above.

Additionally, a rear carry handle 4318 can be provided on the rearsurface of the insulating device 4010 to oppose the closure 4311, whichcan be used by the user to grasp during opening and closing theinsulating device 4010 to make it easier for the user to open and closethe closure 4311. The rear carry handle 4318 may also be used forhanging the insulating device 4010 for drying the inner chamber 4504, orfor carrying the insulating device 4010. Each of the carry handles 4210,shoulder strap 4218, webbing loops 4224, and attachment points 4213 canbe reinforced by one or more of additional structures in the form ofwebbing or suitable polymeric materials. This reinforcement material maybe applied to any of the examples discussed herein.

Also as shown in FIGS. 17 and 21 a binding 4518 can be included thatextends over the top of the insulating device 4010 to secure the outershell 4501 to the inner liner 4500. The binding 4518 can be folded overthe top of the insulating device 4010 and then stitched over the overouter shell 4501 and the inner liner 4500 to form a cover to the jointor seam between the inner liner 4500 and the outer shell 4501. As shownin FIG. 18, the binding 4518 can be folded into thirds to form a firstfolded portion 4518 a where the first third is attached to a first sideof the insulating device 4010, the second third is extends over the topof the insulating device 4010, and the last third is attached to asecond side of the insulating device 4010. The binding 4518 covers theseam between the outer shell 4501 and the inner liner 4500 along the topof the insulating device 4010. Also, as shown in FIG. 17, the binding4518 extends from the top of the insulating device 4010 and forms asecond folded portion 4518 b where the binding 4518 is folded in halfand a third unfolded portion 4518 c, which forms and extends toattachment points 4213 that receive rings 4214. Each side of theinsulating device 4010 can include a second folded portion 4518 b and athird unfolded portion 4518 c such that the insulating device 4010 caninclude two second folded portions 4518 b and two third unfoldedportions 4518 c. The binding 4518 can unfold closer to the attachmentpoints 4213 and may also be formed unfolded from the attachment points4213 to the top of the insulated device 4010. In either of theseconfigurations, a section of the binding 4518, e.g., the second foldedportion 4518 b, can be unattached to the insulating device 4010 andforms a strap between the folded portion 4518 a and the attachmentpoints 4213. In this example, two straps can be formed by the two secondunfolded portions 4518 b and can be grasped by the user for handling theinsulating device, can be used for hanging the insulating device 4010for drying, and the like. Also, the attachment points 4213 formed by thebinding 4518 can be a loop or slot for receiving the rings 4214.

FIGS. 22 and 22A show the insulating layer 4502 in additional detail,which is similar to the example insulating device 4010 discussed abovewhere like reference numerals represent like components with the same orsimilar functionality. The insulating layer 4502 can be formed of thematerials as discussed herein and, in certain examples, can be PVC freeand/or can have non-thermoset properties such that the foam is fullyresilient.

Like the above examples, the upper portion 4502 a of the insulatinglayer 4502 can be formed of a single sheet of material which is rolledinto the shape defined by the opening between the inner liner 4500 andthe outer shell 4501. As shown in FIG. 22, the insulating layer 4502,like in the above examples, can be formed of a first portion or an upperportion 4502 a and a second portion or base portion 4502 b. The rear topflap 4502 a 1 can be formed in smaller rectangular shape. The rear topflap 4502 a 1 extends higher than the front side of the first portion4502 a of the insulating layer 4502 a to accommodate for the frontfacing closure 4311. Specifically, the rear top flap 4502 a 1 can extendto a first height H₃, and the first portion 4502 a can extend to asecond height H₄, and the first height H₃ can be greater than the secondheight H₄. Additionally, as shown in FIG. 22, a majority of theinsulating layer 4502 can extend to the second height H₄. Alternatively,as shown in FIG. 22A, the rear half of the insulating layer 4502 canextend to the first height H₃ and the front half of the insulating layer4502 can extend to the second height H₄. Additionally, as shown in FIG.22A, the insulating layer 4502 can taper from the first height H₃ to thesecond height H₄. Also, this provides the areas of the insulating layer4502 near the top with tapered or chamfered portions along the sides ofthe insulating device 4010 to provide a smaller profile on each side ofthe insulating device 4010.

In one example, the first portion 4502 a can define a first area A₁, andthe rear top flap 4502 a 1 can define a second area A₂, which is smallerthan the first area A₁. When installed between the inner liner 4500 andthe outer shell 4501, the insulating layer 4502 generally follows theconical and trapezoidal shape of the profile of the insulating device4010. Additionally, the upward tapered profile of the outer shell 4501and the inner liner 4500 can help to position the insulating layer 4502such that the insulating layer covers a majority of the inner liner4500.

In particular, as shown in FIG. 21, the insulating layer 4502 occupies amajority of the space formed between the inner liner 4500 and the outershell 4501. The insulating layer 4502 extends substantially to the topof the insulating device 4010 in both the front and the rear portions ofthe insulating device 4010 to insulate a majority of the compartment4504. As a result, the insulating layer 4502 surrounds substantially theentire inner chamber 4502 to provide a maximum amount of insulation tothe inner chamber 4504 of the insulating device 2010. In one example,the insulating layer 4502 covers 80% or more of the inner liner 4500covering the inner chamber 4504, and in particular examples theinsulating layer 4502 covers 85%, 90%, or 95% or more of the inner liner4500 covering the inner chamber 4504.

In the examples discussed in relation to FIGS. 11-22, the front facingclosures 2311, 4311 can be formed such that they extend a majority ofthe way along the front facing surface of the insulating devices 2010,4010. As discussed above, the front-facing closures 2311, 4311 can beformed as zipper closures in accordance with the examples discussedherein. In one example, the closures 2311, 4311 can be substantiallywaterproof or highly water resistant and can be water tight and airtight. The front facing closures 2311, 4311 can be formed as long aspossible in the front facing surface of the insulating devices 2010,4010 to provide for extended user accessibility and visibility of thecontents stored in the insulating devices 2010, 4010. In one example,the closures 2311, 4311 can define a first length L₁, and the topportion of the insulating device 4010 can define a second length L₂.

In one example, L₂ can be 3 cm to 10 cm longer than L₁, the length ofthe front facing closures 2311, 4311 and in one specific example can be5 cm longer than the front-facing closures 2311, 4311. The closures2311, 4311 first length L₁ can extend at least 80% of the second lengthL₂ and up to 98% of the second length L₂. In one particular example, thelength of the closures 2311, 4311, L₁ can extend across 87% of thesecond length L₂.

Additionally, the length L₁ of the front-facing closures 2311, 4311 canbe formed longer than the length L₃ of the bases of the insulatingdevices 2010, 4010. In certain examples, the front facing closures 2311,4311 can be formed approximately 1% to 25% longer than the length L₃ ofthe bases of the insulating devices 4010. In one specific example thelength L₁ of the front facing closures 2311, 4311 can be 10% longer thanthe length L₃ of the bases. For example, the front-facing closureslength L₁ can be formed 3 cm to 12 cm longer than the length L₃ of thebases of the insulating devices, and, in one particular example, thelength L₁ of the front facing closures 2311, 4311 can be 5 cm longerthan the length L₃ of the base.

In still other embodiments, the insulating device can include a closurethat extends around the entire perimeter or a majority of the perimeterof the insulating device and a front facing closure 2311, 4311 asdiscussed above. In this particular example, the contents of theinsulating device can be easily accessed by the user once the entire ora majority of the top portion is removed or through the closure 2311,4311.

In another example, the insulating device can be formed modular suchthat the top and/or the bottom can be removed and multiple structurescan be interconnected to form larger or smaller insulating devices. Forexample, the insulating device can be formed of different sections byway of removable fasteners, such as snaps, zippers, threads, seals, hookand loop, and the like.

In relation to the examples discussed herein, a series of vents can beprovided along the outer shells of the insulating devices. The ventsallow for any gases that are trapped between the inner liner and theouter shell to escape. Without the vents, the gases trapped between theinner liner and the outer shell can cause the insulating device toexpand, which in certain instances, may not be desired. In certainexamples, the one or more joints or seams that connect the variousportions of the outer shell provide vents for gases. Vents can beprovided in areas of the outer shell where the outer shell fabric ispierced. For example, tiny openings can be provided at any of thestitching locations where the various components are located on theinsulating devices. Specifically, the vents can be provided in the areaswhere the handles, molle loops, straps, reinforcement patches, bindings,D-rings, loop patches, etc. are attached to the outer shell of theinsulating device. For example, stitching that may be used to securethese components to the outer shell provides openings into the outershell, which creates venting between the insulation layer and the outershell. In one specific example, the insulating device may vent throughbinding 4518.

The example insulating device 4010 was tested to determine iceretention. As such, the ice retention testing may be utilized todetermine insulative properties of example insulating device 4010. In anexemplary test, the duration of the increase from 0° F. to 50° F. whenthe insulating device 4010 was filled with ice was determined accordingto the test parameters below. In certain examples, the temperature ofthe insulating device increases from 10° F. to 32° F. in a duration of24 hours to 24 hours, the temperature of the insulating device increasesfrom 32° F. to 50° F. in a duration of 36 hours to 68 hours, and thetemperature of the insulating device increases from 0° F. to 50° F. in aduration of 70 hours to 90 hours.

The ice retention was tested using the following test. More than 24hours before the test, the following steps are performed:

-   -   Ensure test coolers are clean inside and out.    -   Mark test coolers with unique identifier and record identifier        and description in test log or notes.    -   Using duct tape, place a thermocouple (T) in the approximate        center of the test cooler (C).    -   The thermocouple tip should be approximately 1 inch above the        cooler floor. (See FIG. 23 for an example of proper thermocouple        set-up.)    -   Condition test coolers by keeping test coolers inside (ambient        temperature 65-75° F.) with lids open for a minimum of 24 hours.    -   Calculate the amount of ice required for testing (to nearest 0.1        lbs.) using the equation below.

Ice per cooler=0.52 lbs.×Quart capacity of cooler

Ice required=Ice per cooler×number of coolers

-   -   Condition the ice by placing the ice in a freezer (−15 to −5°        F.) for a minimum of 24 hours prior to use.

The day of the test, the following steps are performed:

-   -   Gather Test Equipment    -   Allow thermal chamber to reach a temperature of 100° F.    -   Scale—place scale near freezer with test ice    -   Data Logger—ensure Data Logger has charged battery

The test procedure is as follows:

-   -   Bring test coolers to freezer with test ice.    -   Place test cooler on scale and tare the scale.    -   Break test ice with hammer.    -   Using the scale as reference, quickly fill the test cooler with        the required amount of ice.    -   Ensure that the ice is evenly distributed throughout the test        cooler.    -   Ensure that the connector end of the thermocouple is outside of        the test cooler and close and secure the cooler lid.    -   Repeat steps for the remaining test coolers.    -   Arrange the coolers in the test area such that they all have        even amounts of direct sunlight and airflow (one cooler does not        block the other).    -   Connect all thermocouples to the data logger.    -   Check all thermocouple readings to ensure that all connections        are complete and the channels are recording properly. (Note: The        starting temperature inside each test cooler should be <10° F.).    -   Power up the data logger and configure to record with        temperatures recorded at less than 10 minute intervals.    -   Begin recording and note time in test log.    -   Allow the test to continue until the inside temperature of each        test cooler is >50° F.    -   Stop recording.    -   Disconnect thermocouples from data logger.    -   Receive data from data logger.    -   Remove test coolers from test area.    -   Empty test coolers and allow them to dry.    -   Remove thermocouples from test coolers

The heat gain rate of the insulating devices 2010, 4010 can beapproximately 0.5 to 1.5 degF/hr, and, in one particular example, theheat gain rate can be approximately 1.0 degF/hr.

Like in the above examples, the ability of the insulating devices 2010and 4010 are also configured to withstand interior leaks and were alsotested to see how well the insulating devices 2010, 4010 maintain thecontents stored in the storage compartment or receptacles 2504, 4504. Inone example test, the insulating devices 2010, 4010 can be filled with aliquid, such as water, and then can be inverted for a predetermined timeperiod to test for any moisture leaks. In this example, the insulatingdevices 2010, 4010 are filled with a liquid until approximately half ofa volume of the receptacle 4504 is filled, e.g. 3 gallons of water, andthe closures 2301, 4301 are then closed fully. The entire insulatingdevices 2010, 4010 are then inverted and held inverted for a time periodof 30 minutes. The insulating devices 2010, 4010 are then reviewed forany leaks.

The insulating devices 2010, 4010 can be configured to withstand beingheld inverted for 30 minutes without any water escaping or leaving thereceptacles 2504, 4504. In alternative examples, the insulating devices2010, 4010 can be configured to withstand being held inverted for 15minutes to 120 minutes without any water escaping or leaving thereceptacles 2504, 4504.

FIGS. 24-32 show another example insulating device 3010. The exampleinsulating device 3010 can be of a similar construction to the aboveexamples, where like reference numerals represent like features havingsimilar functionality. In this example, as can be seen in FIGS. 24-26and 32, the closure 3311 and opening 3512 is formed through a firstsidewall 3507A, a second sidewall 3705B, and a third sidewall 3507C andpartially through a fourth sidewall 3507D of the insulating device 3010.Moreover, the opening 3512 is configured to provide access to the innerchamber 3504 as is shown in FIGS. 29A and 32. Like in the aboveexamples, the closure 3311 can be substantially waterproof so as toresist liquid from exiting the opening 3512 when the insulating device3010 is in any orientation.

As shown in the cross-sectional view of FIG. 29A, the example insulatingdevice 3010 generally includes a body assembly 3350 and a lid assembly3300, which together form the three main components of the insulatingdevice 3010: the inner liner 3500, the insulating layer 3502, and theouter shell 3501. The inner liner 3500 can, in one example, be formed ofdouble laminated TPU nylon fabric, the insulating layer 3502 can, in oneexample, be formed of can be formed of NBR/PVC foam blend or any othersuitable blend or foam, and the outer shell 3501 can, in one example, beformed of TPU nylon fabric. It is also contemplated that the inner linerand the outer shell 3501 can be formed of one or more of PVC, TPU coatednylon, coated fabrics, and other weldable and/or waterproof fabrics.

As shown in FIGS. 24-26, the closure 3311 extends between the bodyassembly 3350 and the lid assembly 3300 to substantially seal the bodyassembly 3350 and the lid assembly 3300 from water. Additionally, asshown in FIG. 29A, the lid assembly 3300 can be connected to the bodyassembly 3350 by the outer shell 3501, which forms a living hinge 3503.In one example, the living hinge 3503 can be formed as a portion of theouter shell 3501 and/or the inner liner 3500 and specifically from theflexible nature of the material of the outer shell 3501 and/or the innerliner 3500 to provide a larger opening in the insulating device 3010.The living hinge 3503 can also be reinforced by an inner piece of fabric3503A, which can be formed of the inner liner material or otherwaterproof materials. In this way, the chamber 3504 and contents of theinsulating device 3010 can be accessed by opening the closure 3311 andfolding back or opening the lid assembly 3300.

In this example, the insulating device 3010 can be in the shape of acuboid or prism. For example, the outer shell 3501, the insulating layer3502, and the inner liner 3500 define the first sidewall, 3507A, thesecond sidewall 3507B, the third sidewall 3507C, and the fourth sidewall3507D of the cuboid. Also the lid assembly 3300 forms a top wall 3300 aand the base 3215 forms a bottom wall 3215 a to enclose the cuboid.However, the contents of the insulating device 3010 are accessed throughthe opening 3512 formed at the top of the insulating device and againcan extend through each of the first sidewall, 3507A, the secondsidewall 3507B, the third sidewall 3507C and can extend partly throughthe fourth sidewall 3507D. Other shapes are also contemplated for theinsulating device 3010, for example, cylindrical, spherical, conical,pyramidal, frusto-conical, frusto-spherical, frusto-pyramidal, etc. Theheight of the insulating device 3010 can, in one example, be in therange of 15 cm to 50 cm and in one particular example can be 29 cm. Thelength of the insulating device 3010 can be in the range of 15 cm to 50cm and in one particular example can be 32 cm. Also the width of theinsulating device can, in one example, be in the range of 15 cm to 50 cmand in one specific example be 25.5 cm. The storage capacity of theinsulating device 3010 can be 10 to 15 quarts and in one particularexample can be 12.7 quarts. However, it is contemplated that theinsulating device 3010 may comprise any height, length, width and volumedimensions, without departing from the scope of these disclosures.

Like in the above examples, the insulating device 3010 can include oneor more handles 3210, 3212, rings 3214, and webbing loops 3224 forattaching various items, e.g. straps (shoulder), carabineers, dry bags,keys, storage cases, etc. The rings 3214 can be D-rings, and a shoulderstrap (not shown) can be connected to the D-rings for easy carrying ofthe insulating device. Also the rings 3214 can be attached to theinsulating device 3010 at attachment points 3213, which can form loopsor straps 3315 a that also form a slot for receiving the rings 3214. Theinsulating device may also include side, front and/or rear carryhandles, pockets, tie downs, and D-rings anywhere on the externalsurface of the outer shell. The pockets can be sized for receiving keys,phones, wallets, etc. and can be formed waterproof. The pockets may alsoinclude a waterproof zipper to prevent the contents therein from gettingwet.

Likewise, similar to the above examples, the outer shell 3501 can alsoinclude multiple reinforcement areas or patches 3320 that are configuredto assist in structurally supporting the optional handles, straps, andwebbing loops (e.g. 3210, 3212, 3213, 3214, and 3224). The handles orstraps (e.g. 3210, 3212, 3213, 3214, and 3224) and other attachments canbe stitched to the patches using threads 3222. In certain examples,these threads 3222 do not extend through the outer shell 3501 into theinsulating layer 3502. The optional handles or straps can be sewn to thepatches 3320, and the patches 3320 can be RF welded to the outer shell3501. Also, in other examples, the patches 3320 can be sewn or adheredto the outer shell 3501. Apertures from the stitching operation canprovide venting to the interior defined by the outer shell 3501 and theinner liner 3500 of the insulating device 3010. In addition, othertechniques are contemplated for securing the handles or straps to theinsulating device 3010.

The internal components of the insulating device 3010, the body assembly3350, and the lid assembly 3300 can be seen in the cross-sectional viewof FIG. 29A. In addition, FIG. 29B shows a magnified cross-sectionalview of the lid assembly 3300.

The lid assembly 3300 includes an upper inner liner portion 3500A, anupper insulating layer portion 3502A and an upper outer shell portion3501A. The upper insulating layer portion 3502A can be formed of asingle layer of foam, which corresponds to the overall shape of the lidassembly 3300. The foam can, in one example, be an insulating foam, asdiscussed herein, which can be the same foam as is used in the bodyassembly 3350, and can be unattached to and floating between the upperinner liner portion 3500A and the upper outer shell portion 3501A. Asshown in FIG. 29B, the upper inner liner portion 3500A can be formed ofa sheet of material 3500A1 and a strip of material 3500A2 that isattached to the binder 3518. In other embodiments the sheet of material3500A1 can connect directly to the binder 3518 thus eliminating the needfor the strip of material 3500A2. The strip of material 3500A2 canoverlap and be welded to the sheet of material 3500A1. Seam tape 3509can be placed over the connection between the sheet of material 3500A1and the strip of material 3500A2. It is also contemplated that the upperinner liner portion 3500A can be formed as a unitary structure byinjection molding, for example.

The upper inner liner portion 3500A can be connected to the upper outershell portion 3501A by joining the upper inner liner strip of material3500A2 to an upper outer shell strip of material 3501A3 at a RF weldjoint 3522. However, it is contemplated that other types of securingmethods could be used such as other forms of welding, stitching,adhesives, rivets, etc. Additionally, as will be discussed in furtherdetail, a binding material 3518, in the form of a strip or band can besewn over the ends of the upper inner liner strip of material 3500A2 andthe upper outer shell strip of material 3501A3. It is also contemplatedthat the binding material 3518 can be coupled over the ends of the upperinner liner strip of material 3500A2 and the upper outer shell strip ofmaterial 3501A3 by a plurality of rivets, or by using one or moreadhesives.

As shown in FIGS. 29A and 29B, the upper outer shell portion 3501A ofthe lid assembly 3300 may include two separate layers 3501A1, 3501A2 andan upper outer shell strip of material 3501A3 extending perpendicular tothe two separate layers 3501A1, 3501A2. The upper outer shell strip ofmaterial 3501A3 can be integral and attached to a first outer shellsection 3501B1 as discussed in further detail below. For example, theupper outer shell strip of material 3501A3 and the first outer shellsection 3501B1 can be formed or cut from the same material. However, itis also contemplated that outer shell strip of material 3501A3 and thefirst outer shell section 3501B1 are formed of separate structures ordifferent materials. In one example, the top layer 3501A1 can be formedof a TPU coated nylon laminate, and the bottom layer 3501A2 can beformed of a compression molded EVA material. The upper outer shellportion 3501A may also be formed of a unitary piece of material in aninjection molding process, for example.

As shown in FIGS. 29A and 29B, the binding material 3518 can both securethe lid assembly 3300 together and secure the lid assembly 3300 to thebody assembly 3350. The binding material 3518, in certain examples, canbe formed of a strip, band or ribbon and can be made of nylon. It iscontemplated that the binding material 3518 can be formed fromadditional or alternative polymers, without departing from the scope ofthese disclosures. Specifically, the first outer shell section 3501B1can be secured together with the upper inner liner 3500A, the separatelayers 3501A1, 3501A2, and the upper outer shell strip of material3501A3 of the upper outer shell portion 3501A by stitching the bindingmaterial 3518 around the perimeter of the lid assembly 3300. Thestitching, therefore, extends through the binding material 3518, thelower outer shell portion 3501B, the upper inner liner portion 3500A,the top layer 3501A1, the bottom layer 3501A2 and the strip of material3500A2 to form a seam 3517.

The weld joint 3522 can also both secure the lid assembly 3300 togetherand secure the lid assembly 3300 to the body assembly 3350. As alludedto above, the weld joint 3522, which can be an RF weld joint, alsosecures the lid assembly 3300 together by connecting the upper innerliner portion 3500A and the upper outer shell portion 3501A by joiningthe upper inner liner strip of material 3500A2 to an upper outer shellstrip of material 3501A3. It is also contemplated, however, that thejoint 3522 could be formed by stitching or by an adhesive. Again oncethe lid assembly 3300 and the body assembly 3350 are secured together,the living hinge 3503 is formed between the lid assembly 3300 and thebody assembly 3350.

The lid assembly 3300 and the body assembly 3350 are also connected bythe closure, which as discussed below, in one example, can be a zipper.Specifically, zipper tape 3306 can be attached between the upper outershell strip of material 3501A3 and the first outer shell section 3501B1of the lower outer shell portion 3501B by stitching, welding, adhesives,etc. In this way, an upper portion 3306 a and a lower portion 3306 b ofthe zipper tape 3306 secures the lid assembly 3300 and the body assembly3350 together.

Referring again to FIG. 29A, the body assembly 3350 includes lower innerliner portion 3500B, lower insulating layer portion 3502B, and lowerouter shell portion 3501B. The lower inner liner portion 3500B can beformed of a top strip 3500B1, a middle portion 3500B2, and a bottomportion 3500B3. The top strip 3500B1, the middle portion 3500B2, and thebottom portion 3500B3 can be welded or stitched together at seams 3508.The seams 3508 can be covered with a seam tape 3509, which can be formedof a waterproof or water resistant material, such as PU (polyurethane).However, the seam tape 3509 can be formed of a breathable material thatis impervious to water but allows gases to escape from the in the innerchamber 3504.

In an alternative example, the lower inner liner portion 3500B can beformed of a single integral piece by, for example, injection molding.FIG. 31 shows an example inner liner portion 7500B that is formed by aninjection molding process. In this example, the lower inner linerportion 7500B can be formed of one or more of urethane, PVC, TPU, orother weld-able material. The lower inner liner portion 7500B can bewelded into place onto the outer shell, after the lower insulating layeris placed within the outer shell.

Referring again to FIGS. 29A and 30, the lower insulating layer portion3502B can include a first sheet of insulating material 3502B1 and asecond sheet of insulating material 3502B2. Similar to the aboveexamples, the first sheet of insulating material 3502B1 and the secondsheet of insulating material 3502B2 can be free floating layers ofinsulating material that are not attached to either the lower innerliner portion 3500B or the lower outer shell portion 3501B. However, itis also contemplated that the first sheet of insulating material 3502B1and the second sheet of insulating material 3502B2 can be attached toeither the lower inner liner portion 3500B or the lower outer shellportion 3501B. Moreover, it is also contemplated that the lowerinsulating layer portion 3502B be formed of a single unitary piece.

The lower outer shell portion 3501B can be formed of several sections.In this example, the lower outer shell portion 3501B can include a firstouter shell section 3501B1, a lower outer wall section 3501B2, a firstbase layer 3501B3, and a second base layer 3501B4. Similar to the lidassembly, the first base layer 3501B3 can be formed of a TPU coatednylon laminate, and the second base layer 3501B4 can be formed of acompression molded EVA material. Each of the lower outer wall section3501B2, the first base layer 3501B3, and the second base layer 3501B4can be joined together by stitching, welding or adhesives. Also like inthe above examples, a base support ridge 3400 can be formed into thefirst base layer 3501B3 and the second base layer 3501B4 to provide forstructural integrity and support to the insulating device 3010 when theinsulating device 3010 is placed onto a surface. In alternativeexamples, the lower outer shell portion 3501B can be formed as asingular component and may, in certain examples, be formed by aninjection molding process.

Like in the above examples, the closure 3311 can be a zipper and can besubstantially waterproof. Moreover, the zipper may comprise a pull tabor handle 3302, which in this example can formed of a hard plastic. Itis also contemplated that the pull tab 3302 can be formed of a metal oralloy, a flexible polymer, cloth, string, or rope, among others. Formingthe pull tab 3302 of a cloth, string, or rope may prevent the wear ofthe connection between the pull tab 3302 and the zipper. Specifically,when the zipper is closed about the circumference of the outer shell3501, the pull tab 3302 can be rotated or twisted by the user. Thecloth, string, or rope can withstand the twisting action by the user.Other pull tabs are also contemplated. For example, the pull tab couldbe provided with a bearing connection that allows the pull tap to berotated 360° in all directions.

A series of vents can be provided along the outer shell 3501 of theinsulating device 3010. The vents allow for any gases that are trappedbetween the inner liner 3500 and the outer shell 3501 to escape. Withoutthe vents, the gases trapped between the inner liner 3500 and the outershell 3501 will cause the insulating device 3010 to expand, which incertain instances, may not be desired. In certain examples, the joint orseams that connect the inner liner and the outer shell provides a ventto gases.

The venting can be provided in the lid assembly 3300. Specifically inthe lid assembly 3300, the seam 3517 may provide a series of smallopenings in the lid assembly 3300 where the stitching on the bindermaterial 3518 occurs. These openings act as vents for gases to escapethe inner volume of the lid assembly 3300.

Moreover, venting can be provided in the body assembly 3350. In the bodyassembly, the vents can be provided in areas of the lower outer shellportion 3501B where the lower outer shell portion 3501B fabric ispierced. For example, as shown in FIG. 26, tiny openings can be providedat the box and cross-shaped stitching 3521 where the rear carry handle3210 is attached to the insulating device 3010. The vents can also beprovided in the areas or locations where the handles 3212, 3210, molleloops 3224, and D-rings 3214 are attached to the outer shell 3501 of theinsulating device 3010. For example, the stitching that secures thehandles, webbing or molle loops 3224, and D-rings 3214 to the outershell provides openings into the outer shell 3501 to create venting tothe storage compartment or inner chamber 3504 of the insulating device3010. FIG. 33 shows an example schematic where stitching 3519 extendsthrough the outer shell 3501, a handle 3212 a reinforcement areas orpatches 3320.

To form the insulating device 3010, the body assembly 3350 can be formedand then the lid assembly 3300 can be formed by joining the lid assembly3300 to the body assembly 3350. To form the body assembly 3350 of theinsulating device 3010, the lower outer shell portion 3501B and thelower inner liner portion 3500B can be formed independently. Once thelower outer shell portion 3501B is formed, the insulating layer 3502 canthen be placed within the lower outer shell portion 3501B. The lowerinner liner portion 3500B can be attached to the lower outer shellportion 3501B to secure the insulating layer 3502 within the lower outershell portion 3501B and the lower inner liner portion 3500B. However,the insulating layer 3502 can freely float between the lower outer shellportion 3501B and the lower inner liner portion 3500B. The lid assembly3300 can be secured together and the lid assembly 3300 can be secured tothe body assembly 3350 by welding the upper inner liner portion 3500A tothe upper outer shell portion 3501A and the lower outer shell portion3501B at the weld joint 3522. Finally, the lid assembly 3300 can befurther attached to the lower outer shell portion 3501B by way ofstitching the top portion of the lower outer shell portion 3501Btogether with the top layer 3501A1, the bottom layer 3501A2, the upperinner liner portion 3500A, the strip of material 3501A3, and the bindingmaterial 3518.

Specifically, the lower outer shell portion 3501B can be formed byattaching each of the first outer shell section 3501B1, the lower outerwall section 3501B2, the first base layer 3501B3, and the second baselayer 3501B4 together. Next, each of the first sheet of insulatingmaterial 3502B1 and the second sheet of insulating material 3502B2 canbe placed within the lower outer shell portion 3501B. The lower innerliner portion 3500B can then be formed by welding each of the top strip3500B1, the middle portion 3500B2, and the bottom portion 3500B3together and then by adding the seam tape 3509 over each of the welds.Alternatively, as discussed above, the lower inner liner portion 3500Bcan be formed by injection molding the material. Once the lower innerliner portion 3500B is formed, the inner liner portion 3500B can beplaced within the lower insulating layer portion 3502B, and the innerliner portion 3500B can be welded to the lower outer shell portion 3501Bat seam 3511 all along the inner perimeter of the body assembly 3350 ofthe insulating device 3010. The seam 3511 can be formed in this exampleby either welding or stitching.

FIG. 9 shows an exemplary welding technique that can be used to weld thelower inner liner portion 3500B to the lower outer shell portion 3501B.Once the lower inner liner portion 3500B is placed within the lowerinsulating layer portion 3502B, the lower inner liner portion 3500B canthen be joined to the lower outer shell portion 3501B on its side usinga three-piece tool, which can include a top U-shaped portion 3514A, aplate portion 3516, and a bottom U-shaped portion 3514B. The curvatureof the top U-shaped portion 3514A, the plate portion 3516, and thebottom U-shaped portion 3514B, can correspond to the shape of theperimeter of the body assembly 3350 of the insulating device 3010.

To form the seam 3511 as a weld, the lower inner liner portion 3500B isplaced into contact with the lower outer shell portion 3501B and theplate portion 3516 is placed within the lower inner liner portion 3500Band the top U-shaped portion 3514A, and the bottom U-shaped portion3514B can be placed into contact with lower outer shell portion 3501B.The top U-shaped portion 3514A and the bottom U-shaped portion 3514B canbe connected to two lead wires such that current can pass through thetop U-shaped portion 3514A, the lower outer shell portion 3501B and thelower inner liner portion 3500B. Current can then be applied first tothe top U-shaped portion 3514A to form a weld along the top U-shapedportion 3514A including the curves and the straight portions. After thetop section is welded, the polarity of the lead wires can then bereversed to then weld the bottom section along the bottom U-shapedportion 3514B.

After the bottom section is welded by the bottom U-shaped portion theremaining two sides can then be welded by using the plate portion 3516and a pair of straight side bars or another clamping mechanism or vice.Similar to the curved portions of the body assembly 3350, current can beapplied to the pair of straight side bars by lead wires.

Again, the sides can be welded separately by applying the current in afirst direction to weld a first side and by then switching polarity ofthe leads and running the current in the opposite direction to weld asecond side. In one example, each of the sections can be welded forapproximately 10 seconds. Once the weld is complete around the entireperimeter of the body assembly 3350, the body assembly 3350 can beassembled to the lid assembly 3300.

In one example, the closure 3311 can be substantially waterproof so asto resist liquid from exiting the opening when the insulating device isdropped from a distance of six feet. In this test, the insulating devicecan be filled completely with water and then dropped from six feet ontoa concrete surface on each of the faces of the insulating device 3010,which in this case is six.

The example insulating device 3010 was tested to determine iceretention. As such, the ice retention testing may be utilized todetermine insulative properties of example insulating device 3010. In anexemplary test, the duration of the increase from 0° F. to 50° F. whenthe insulating device 3010 was filled with ice was determined accordingto the test parameters below. In certain examples, the temperature ofthe insulating device increases from 0° F. to 10° F. in a duration of0.5 hours to 1.5 hours, the temperature of the insulating deviceincreases from 10° F. to 50° F. in a duration of 22 hours to 28 hours,and the temperature of the insulating device increases from 0° F. to 50°F. in a duration of 24 hours to 30 hours.

The ice retention was tested using the following test. More than 24hours before the test, the following steps are performed:

Ensure test coolers are clean inside and out.

Mark test coolers with unique identifier and record identifier anddescription in test log or notes.

Using duct tape, place a thermocouple (T) in the approximate center ofthe test cooler

(C).

The thermocouple tip should be approximately 1 inch above the coolerfloor. (See FIG. 11 for an example of proper thermocouple set-up.)

Condition test coolers by keeping test coolers inside (ambienttemperature 65-75° F.) with lids open for a minimum of 24 hours.

Calculate the amount of ice required for testing (to nearest 0.1 lbs.)using the equation below.

Ice per cooler=0.52 lbs.×Quart capacity of cooler

Ice required=Ice per cooler×number of coolers

Condition the ice by placing the ice in a freezer (−15 to −5° F.) for aminimum of 24 hours prior to use.

The day of the test, the following steps are performed:

Gather Test Equipment

Allow thermal chamber to reach a temperature of 100° F.

Scale—place scale near freezer with test ice

Data Logger—ensure Data Logger has charged battery

The test procedure is as follows:

Bring test coolers to freezer with test ice.

Place test cooler on scale and tare the scale.

Break test ice with hammer.

Using the scale as reference, quickly fill the test cooler with therequired amount of ice.

Ensure that the ice is evenly distributed throughout the test cooler.

Ensure that the connector end of the thermocouple is outside of the testcooler and close and secure the cooler lid.

Repeat steps for the remaining test coolers.

Arrange the coolers in the test area such that they all have evenamounts of direct sunlight and airflow (one cooler does not block theother).

Connect all thermocouples to the data logger.

Check all thermocouple readings to ensure that all connections arecomplete and the channels are recording properly. (Note: The startingtemperature inside each test cooler should be <10° F.).

Power up the data logger and configure to record with temperaturesrecorded at less than 10 minute intervals.

Begin recording and note time in test log.

Allow the test to continue until the inside temperature of each testcooler is >50° F.

Stop recording.

Disconnect thermocouples from data logger.

Receive data from data logger.

Remove test coolers from test area.

Empty test coolers and allow them to dry.

Remove thermocouples from test coolers

Two samples were tested according to the above procedure. The results ofwhich are reflected below.

Time from Time from Time from 0° F. to 10° F. 0° F. to 50° F. 10° F. to50° F. Time (mins.) Days Hrs Min Days Hrs Min Test 53 1 3 53 1 3 0 #1Test 49 1 3 37 1 2 48 #2

FIGS. 35A-36B show various views of another exemplary insulating device5010. The example insulating device 5010 is similar to the examplediscussed above in relation to FIGS. 24-30. Like reference numeralsrefer to the same or similar elements of similar functionality in all ofthe various views; and, therefore, these elements are not described indetail. However, in this example the exemplary insulating device 5010can be formed of a smaller size, can include a top handle 5216, and mayinclude an optional reinforcement sheet or panel. Nevertheless, it iscontemplated that the insulating device examples discussed herein couldinclude a similar top handle and reinforcement sheet or panel.

FIGS. 36A and 36B show a partial view of an example lid assembly 5300.FIG. 35A shows a partial cross-section view of the example lid assembly5300. The example lid assembly 5300 is similar to the examples above,however, can additionally include a reinforcement sheet or panel 5217 inthe lid assembly 5300. FIG. 36B shows a partial top view of the examplelid assembly to illustrate the reinforcement sheet 5217. Thereinforcement sheet or panel 5217 is configured to assist in preventingbowing of the handle 5216 and the lid assembly 5300. The reinforcementsheet or panel 5217 can be a relatively rigid sheet of material incomparison to the outer liner 5501, insulating layer 5502, and the innerlayer 5500. In one particular example, the reinforcement sheet or panel5217 can be formed of a suitable polymer or plastic, such aspolyethylene. However, any stiffener material that is flexible could beused and other examples, may include a thermoformed PE, a TPU injectionmolded custom component.

In certain examples, the reinforcement sheet or panel 5217 can be flat,corrugated or may have a honey comb configuration. The panel 5217,however, can include other patterns so as to assist in preventing bowingof the handle 5216. In certain examples, the reinforcement sheet orpanel can be 1 to 3 mm thick. The reinforcement sheet may include acover, which can in certain examples, can be configured to prevent waterfrom penetrating the cover. In other examples, additional fabric may beincluded to reinforce the handle.

A reinforcement area or patch 5320 can be included on the lid assembly5300 for supporting the handle 5216. In certain examples, the patch 5320can be welded to the lid assembly 5300. However, the patch 5320 may alsobe omitted entirely. The handle 5216 may be sewn to the lid assembly5300 and the reinforcement panel 5217 by way of thread 5219. The handle5216 may also extend through the lid assembly and be directed connectedto the reinforcement panel 5217. In addition, instead of using a thread,the handle 5216 can be connected to the reinforcement sheet or panel5217 by one or more welds, bolts or other threaded-like connection,bayonet, ball and socket, and the like. Other connection methods mayinclude providing either layers 5501A1 or 5501A2 with one or more slotsand the reinforcement sheet or panel 5217 with one or more correspondingprojections that can be located within the one or more slots, whichallow for a more advanced connection of the sheet or panel 5217 to thelid assembly 5300 of the insulating device 5010. Also a wireframe orsteel wire can be placed within the handle 5216 and extend through thehandle 5216. The wireframe or steel wire can be threaded through thesheet or panel 5217 to secure the handle to the lid assembly 5300. It isalso contemplated that all or portions of the lid assembly and/or handlecan be injection molded to provide a more rigid structure to preventbowing of the handle.

The connection between the handle 5216 and the reinforcement panel 5217also helps prevent separation issues between the separate layers 5501A1,5501A2, which can be a TPU coated nylon laminate, and a compressionmolded EVA material respectively. In this example, the connectionbetween the handle and the reinforcement panel may allow water into thelid. However, at the same time, the connection can allow for any liquidtherein to escape by evaporating through the opening formed by theconnection. However, it is also contemplated that the connection betweenthe handle and the reinforcement panel may also be waterproof or waterresistant to limit the amount of moisture into the lid assembly.

Also the handle 5216 can be formed of a 1000D Nylon or other suitablepolymer and may include 50 mm webbing. Additionally, the handle 5216 mayinclude padding on the gripping portion of the handle. In one example,the padding may be a suitable foam, such as a 5 mm polyethylene spongefoam. It is contemplated that the seal between the lid assembly 5300 andthe body assembly 5350 can be configured to withstand shock loading bythe handle when the insulating device 5010 is sealed and filled withcontents. Nevertheless, a side bridge linking the lid assembly 5300 tothe body assembly 5350 is also contemplated for transporting heavy itemsin the insulating device 5010.

An exemplary insulating device may include an outer shell, an innerliner, an insulating layer floating freely in between the outer shelland the inner liner, and a waterproof closure. The top of the shell hasfirst perimeter circumference, and the bottom of the shell has a secondperimeter circumference. The first perimeter circumference can be equalto the second perimeter circumference. The closure can be a zipperassembly comprising a plurality of zipper teeth, and the zipper teethcan be formed of plastic or metal. The outer shell can be made of adouble laminated TPU nylon fabric. The inner liner can be made of adouble laminated TPU nylon fabric. The insulating layer can be formed ofa closed cell foam. The insulating layer can be made of a NBR and a PVCblend, and at least a portion of the insulating layer can be constructedwith an EVA foam layer. The outer shell further can include at least oneof a strap or handle. The outer shell further can include at least onering for securing the insulating device.

An exemplary insulating device can include an outer shell, an innerliner, a closure adapted to seal at least one of the outer shell or theinner liner, and an insulating layer between the outer shell and theinner liner. The closure can have a first flange and a second flange,and the outer liner can be secured to top surfaces of the first flangeand the second flange and the inner liner can be secured to bottomsurfaces of the first flange and the second flange. The outer liner andthe inner liner can be connected to the closure by a polymer weld. Theouter shell can have a first circumference and a second circumference,the first circumference and the second circumference both having an ovalshape. The closure can be adapted to be a barrier against fluid. Theclosure can be a zipper apparatus that is watertight up to 7 psi aboveatmospheric pressure.

An exemplary method of assembling a insulating device may includeforming an inner liner having an inner vessel, forming an outer shell,forming an insulating layer between the inner liner and the outer shell,and securing a closure configured to be a barrier against fluidpenetration in and out of the inner vessel wherein the closure issecured in a flat plane and is secured to the outer shell and the innershell. The outer shell and inner shell may only be connected to theclosure and not to the insulating layer between the outer shell andinner liner.

A waterproof polymer weld can be formed between the closure and theinner shell and the closure and the outer shell when the closure, theouter shell, and the inner liner are lying in a horizontal plane. Theouter shell and the inner layer can be formed of a TPU nylon material.The closure can have a first flange and a second flange. The outer linercan be secured to top surfaces of the first flange and the second flangeand the inner liner can be secured to bottom surfaces of the firstflange and the second flange.

The method can also include forming the insulating layer from arectangular shape, and rolling the rectangular shape into a cylindricalshape. The top of the insulating layer has a first perimetercircumference and the bottom of the insulating layer has a secondperimeter circumference. The first perimeter circumference can be equalto the second perimeter circumference.

Another example insulating device can include an outer shell, an innerliner forming a storage compartment, a foam layer floating freely inbetween the outer and inner liner, the foam layer providing insulation,an opening extending through the outer layer and the inner layer, and aclosure adapted to substantially seal the opening. The closure can besubstantially waterproof so as to resist liquid from exiting theopening.

The insulating device can also include an upper wall and a base, theupper wall defining an upper wall circumference, an upper wall lengthand an upper wall width, and the base defining a base circumference, abase length and a base width. The upper wall circumference can be equalto the base circumference and the ratio of the upper wall length to theupper wall width can be greater than the ratio of the base length to thebase width. In one example, a heat gain rate of the insulating devicecan be approximately 1.0-1.5 degF/hr.

Another example method of forming an insulating device may includeforming an inner liner first portion and an outer shell first portion,securing the inner liner first portion and the outer shell first portionto a sealable closure to form a cap assembly, forming an inner linersecond portion and securing the inner liner second portion to the innerliner first portion to form an inner liner, forming an outer shellsecond portion, rolling a rectangular foam portion to form a firstcylindrical foam portion and securing a foam base portion to the firstcylindrical portion to form a foam assembly, inserting the foam assemblyinto the outer shell second portion, inserting the inner liner into thefoam assembly, and stitching the outer shell first portion to the outershell second portion. The inner liner first portion and the outer shellfirst portion can be welded to the closure. The closure can be providedwith at least one flange and the flange can be secured to a bottomsurface of the outer shell first portion and a top surface of the innerliner first portion. The foam can float between the outer shell secondportion and the inner liner second portion.

An example portable insulating device may include an outer liner, aninner liner forming a storage compartment, a foam layer in between theouter and inner liner. The foam layer can be adapted to provideinsulation. The example portable insulating device may also include anopening extending through one of the outer layer and the inner layer anda closing means for substantially sealing the opening. The closure canbe substantially waterproof.

In one example, a portable cooler may include an aperture on the top ofthe cooler that is opened and closed by a zipper apparatus which allowsaccess to a chamber within the cooler. The aperture prevents any fluidleakage out of the cooler if the cooler is overturned or in anyconfiguration other than upright. The zipper assembly also prevents anyfluid from permeating into the cooler chamber if the cooler is exposedto precipitation, other fluid, or submersed under water.

An example method of assembling a zipper apparatus and apertureconfigured to be impervious to water or other liquids and fluids caninclude attachment of a waterproof zipper via material welding to bothan outer shell and an inner liner. This method may result in a chamberimpervious to water and other liquids when the zipper apparatus on theaperture is sealed.

In one example, an insulating device may include an outer shell, aninner liner forming a storage compartment, a foam layer floating formedin between the outer and inner liner, the foam layer providinginsulation, an opening extending through the outer layer and the innerlayer, a closure adapted to substantially seal the opening, the closurebeing substantially waterproof so as to resist liquid from exiting theopening when the insulating device is in any orientation. In oneexample, the top portion of the outer shell can have a first perimetercircumference in a first configuration. The outer shell may include abottom portion, the bottom portion of the outer shell can have a secondperimeter circumference in a second configuration that is different fromthe first configuration, and the first perimeter circumference can beequal to the second perimeter circumference. The first configuration andthe second configuration can be both oval shaped. In one example, theinsulating device may include an upper wall and a base, the upper wallcan define an upper wall circumference, an upper wall length and anupper wall width, and the base can define a base circumference, a baselength and a base width. The upper wall circumference can be equal tothe base circumference and the ratio of the upper wall length to theupper wall width can be greater than the ratio of the base length to thebase width. The cold retention time of the insulating device can beapproximately 11 to 20 hours. However, in one example the cold retentiontime can be 11 to 15 hours. In another example the cold retention timecan be approximately 12.24 hours. The heat gain rate of the insulatingdevice can be approximately 1 to 1.5 degF/hr, and, in one particularexample, the heat gain rate can be approximately 1.4 degF/hr. Thestorage compartment can be configured to maintain a liquid therein whileinverted for greater than 15 minutes. In one particular example, thestorage compartment can be configured to maintain the liquid for aperiod of greater than 30 minutes therein when inverted and a half of avolume of the storage compartment is filled with the liquid.

In one example, the insulating layer can be floating freely in betweenthe outer shell and the inner liner. The insulating layer can be formedof closed cell foam, and the insulating layer can be made of a NBR and aPVC blend. In one example least a portion of the insulating layer can beconstructed with an EVA foam layer. The closure can be a zipper assemblycomprising a plurality of zipper teeth, and the zipper teeth can beformed of plastic.

In one example, the outer shell and the inner liner can be made of adouble laminated TPU nylon fabric. The outer shell further can includeat least one of a strap or handle. The outer shell can include at leastone ring for securing the insulating device. The insulating layer can beconfigured to maintain an internal temperature of the insulating devicebelow 50 degrees Fahrenheit for 65 to 85 hours. The closure can beformed with a first flange and a second flange and the outer liner canbe secured to top surfaces of the first flange and the second flange.The inner liner can be secured to bottom surfaces of the first flangeand the second flange. The outer liner and the inner liner can beconnected to the closure by a polymer weld. In one example, the closurecan be watertight up to 2 to 14 psi above atmospheric pressure. A looppatch may also be provided on the insulating device.

In another example, an insulating device may include an outer shell, aninner liner forming a storage compartment, a foam layer floating inbetween the outer and inner liner, which provides insulation, an openingextending through the outer layer and the inner layer, a closure adaptedto substantially seal the opening. The closure can be substantiallywaterproof so as to prevent liquid from exiting the opening when theinsulating device is inverted for a period of greater than 15 minutes.The heat gain rate of the insulating device can be approximately 1.0 to1.5 degF/hr. The insulting device can include at least one handle. Theat least one handle can be configured to support 100 lbs. to 300 lbs. ofweight for 1 to 10 minutes without showing signs of failure. In oneexample, the insulating device can be configured to withstand 35 lbs. to100 lbs. of puncture force.

An example method of forming an insulating device can include forming aninner liner first portion and an outer shell first portion, securing theinner liner first portion and the outer shell first portion to asealable closure to form a cap assembly, forming an inner liner secondportion and securing the inner liner second portion to the inner linerfirst portion to form an inner liner, forming an outer shell secondportion, rolling a rectangular foam portion to form a first cylindricalfoam portion and securing a foam base portion to the first cylindricalfoam portion to form a foam assembly, inserting the foam assembly intothe outer shell second portion, inserting the inner liner into the foamassembly, and securing the outer shell first portion to the outer shellsecond portion to form the outer shell. The method may also includesecuring a closure configured to be a barrier against fluid penetrationin and out of the inner vessel and forming a waterproof polymer weldbetween the closure and the inner shell and the closure and the outershell when the closure, the outer shell, and the inner liner are lyingin a flat plane.

In an example, the inner liner first portion and the outer shell firstportion can be secured to the closure. The closure can be provided withat least one flange, and the flange can be secured to a bottom surfaceof the outer shell first portion and a top surface of the inner linerfirst portion. The foam can freely float between the outer shell secondportion and the inner liner second portion. The outer shell and innershell are only connected to the closure and not to the insulating layerbetween the outer shell and inner liner. The outer shell can be formedof a TPU nylon material, and the inner liner can be formed from a TPUnylon material. The closure can include a first flange and a secondflange. The outer liner can be secured to top surfaces of the firstflange and the second flange, and the inner liner can be secured tobottom surfaces of the first flange and the second flange. The top ofthe insulating layer can have a first perimeter circumference. Thebottom of the insulating layer can have a second perimetercircumference. The first perimeter circumference can be equal to thesecond perimeter circumference.

In one example, an insulating device can include an outer shell defininga sidewall, an inner liner forming a storage compartment, an insulatinglayer positioned in between the outer shell and the inner liner, theinsulating layer providing insulation for the storage compartment, anopening extending through the outer shell and the inner liner, and aclosure adapted to substantially seal the opening, the closure beingsubstantially waterproof so as to resist liquid from exiting the openingwhen the insulating device is in any orientation. The insulating devicemay include a vertically extending front facing surface and the closurecan be located on the front facing surface. A cross section of theinsulating device can approximate a pentagon in an extended position,and a cross section of the insulating device can approximate a trapezoidin an extended position. The insulating device may also include a base,and the insulating layer can insulate the base. The base may alsoinclude an additional insulating layer.

The insulating device may also include a fold-down portion configured tocover the closure. The fold-down portion comprising a first section anda second section and wherein the first section is free of the insulationlayer and the second section includes the insulation layer. Thefold-down portion can be at least partially free of foam. The fold-downportion can be configured to be secured to the sidewall. The fold-downportion can include at least one hook and the sidewall can include atleast one loop. The hook can be configured to engage the loop to securethe fold-down portion to the sidewall. The fold-down portion can besecured to the sidewall, and the fold-down portion may extend at leastpartly in a substantially horizontal direction. The fold-down portionmay define a first width, and the closure extends across at least 95% ofthe first width. The fold-down portion may also include a handleconfigured to be grasped by a user when the fold-down portion is securedto the sidewall.

The insulating layer may include a foam material. The insulating layermay include a first portion and a second portion, and the second portioncan be formed thicker than the first portion. The insulating layer canbe at least partly formed in a shape of a T. The insulating layer can beat least partly formed of a first rectangle and a second rectangle andthe first rectangle can have a larger area than the second rectangle.The first rectangle can have a first rectangle width and the secondrectangle can have a second rectangle perimeter. The first rectanglewidth can approximates the second rectangle perimeter. The secondrectangle can extend into the fold-down portion. The insulating layercan have a first height and a second height and the first height can begreater than the second height. A majority of the insulating layer canextend to the second height.

A method of forming an insulating device may include forming an innerliner defining a storage compartment, forming an outer shell defining asidewall, placing an insulating layer in between the outer shell and theinner liner, the insulating layer providing insulation for the storagecompartment, placing an opening in the inner liner and the outer shell,and placing a closure between the inner liner and the outer shell. Theclosure can be adapted to substantially seal the opening, and theclosure can be substantially waterproof so as to resist liquid fromexiting the opening when the insulating device is in any orientation.The method may also include forming a fold-down portion configured tocover the closure, providing the fold-down portion with a first sectionand a second section. The first section can be free of the insulationlayer and the second section can include the insulation layer. Thefold-down portion can be at least partially free of foam. The fold-downportion can be configured to secure to the sidewall. The method may alsoinclude forming the insulating layer at least partly in the shape of aT, forming the insulating layer at least partly of a first rectangle anda second rectangle, and forming the first rectangle of a larger areathan the second rectangle. The method may also include extending thesecond rectangle into the fold-down portion and providing the insulatinglayer on a base and providing an additional insulating layer along thebase.

In another example, an insulating device can include an outer shelldefining a sidewall, an inner liner forming a storage compartment, andan insulating layer positioned in between the outer shell and the innerliner. The insulating layer can provide insulation for the storagecompartment. The insulating device can include an opening configured toallow access to the storage compartment and a closure adapted tosubstantially seal the opening. The insulating device can include abinding material, and the binding material can be placed over a jointbetween the inner liner and the outer shell. The binding material can bestitched onto the insulating device, and the stitching can createopenings into the outer shell for venting air trapped between theinsulating layer and the outer shell. The binding material can create atleast one strap for holding the insulating device. The binding materialcan include a first folded portion attached to the outer shell and asecond folded portion, and the second folded portion can form a strap.

The insulation device can approximate a trapezoid from a front view andcan approximate a conical shape from a side view. In one example, theinsulating device increases from 0° F. to 50° F. in a duration of 70hours or greater when filled with 0.52 lbs. of ice per each quart incapacity of the insulating device.

The closure can be substantially waterproof so as to resist liquid fromexiting the opening when the insulating device is in any orientation. Inone example, the insulating device can be configured to withstand beingheld inverted for 15 minutes without any water escaping or leaving thestorage compartment. The closure can be configured to stay in the openedposition when the closure is not sealed. The closure can be a zipper. Inone example, the closure extends at least 80% of the length of theinsulating device when measured along the closure. The length of theclosure can be longer than the length of the bottom of the insulatingdevice, and the length of the closure is at least 5% longer than thelength of the bottom of the insulating device. The insulating device caninclude a vertically extending front facing surface, and the closure canbe located on the front facing surface. A handle can be located on arear facing surface opposing the front facing surface.

In the example insulating device, the insulating layer can comprise afoam material. The insulating layer can comprise a first portion and asecond portion, and the second portion can be formed thicker than thefirst portion. The insulating layer can be at least partly formed of afirst rectangle and a second rectangle, and the first rectangle can havea larger area than the second rectangle. The insulating layer can have afirst height and a second height, and the first height can be greaterthan the second height. In one example, a majority of the insulatinglayer can extend to the second height. In addition or alternatively, thefront of the insulating layer can extend to the second height and therear of the insulating layer extends to the first height. The insulatingdevice can include a base, and the insulating layer can insulate thebase. Also the base can include an additional or separate insulatinglayer. In one example, the insulating layer can cover 80% or more of theinner liner covering the storage compartment or the insulating layer cancover 90% or more of the inner liner covering the storage compartment.

In another example, a method of forming an insulating device may includeforming an inner liner the inner liner defining a storage compartment,forming an outer shell defining a sidewall, placing an insulating layerin between the outer shell and the inner liner, the insulating layerproviding insulation for the storage compartment, placing an opening inthe inner liner and the outer shell, placing a closure between the innerliner and the outer shell, the closure adapted to substantially seal theopening, the closure being substantially waterproof so as to resistliquid from exiting the opening when the insulating device is in anyorientation. The method can also include forming the insulating layer atleast partly of a first rectangle and a second rectangle and forming thefirst rectangle of a larger area than the second rectangle. The methodcan also include providing the insulating layer on a base and providingan additional insulating layer along the base.

An example insulating device can include an outer shell defining a firstsidewall; an inner liner forming a storage compartment; an insulatinglayer positioned in between the outer shell and the inner liner, theinsulating layer providing insulation for the storage compartment. Theouter shell and the inner liner can define an opening, and the openingcan be configured to allow access to the storage compartment. A closurecan be adapted to substantially seal the opening, and the closure can besubstantially waterproof so as to resist liquid from exiting the openingwhen the insulating device is in any orientation. The outer shell mayinclude a second sidewall and a third sidewall, and the opening mayextend through the first sidewall, the second sidewall, and the thirdsidewall. The insulating device can be in the shape of a cuboid. Theinner liner and the outer shell can form a joint, and the joint caninclude a vent to gases that become trapped between the inner liner andthe outer shell. The outer shell may include one or more handles, and avent can be formed adjacent to a location of the one or more handles.The closure can be substantially waterproof so as to resist liquid fromexiting the opening when the insulating device is dropped from adistance of six feet.

The insulating device can also include a lid assembly and a bodyassembly. The lid assembly and the body assembly can together form theinner liner, the insulating layer, and the outer shell. The lid assemblycan include at least a portion of the insulation layer. The lid assemblymay also include a handle and a reinforcement layer that is more rigidthan the inner liner, the insulating layer, and the outer shell.

The outer shell may define a bottom wall extending in a first plane, andthe inner liner can be secured to the outer shell in a second planeextending perpendicular to the first plane. The liner may be formed of afirst piece and a second piece and the first piece is joined to thesecond piece by way of a weld to define a seam and the seam may becovered with a seam tape. In one alternative example, the inner linercan be formed by way of injection molding. The closure can be a zipperand can be substantially waterproof. The zipper can include a pull, andthe pull can be formed of a cloth, string, or rope. In certain examples,the temperature of the insulating device increases from 0° F. to 10° F.in a duration of 0.5 hours to 1.5 hours, the temperature of theinsulating device increases from 10° F. to 50° F. in a duration of 22hours to 28 hours, and the temperature of the insulating deviceincreases from 0° F. to 50° F. in a duration of 24 hours to 30 hours.

An example method may include forming a body assembly by forming a lowerouter shell, placing a lower insulating layer into the lower outershell, and securing a lower inner liner portion to the lower outershell; forming a lid assembly of an upper outer shell, an upper innerliner portion and an upper insulating layer therebetween; and joiningthe lid assembly to the body assembly by securing a closure between thelid assembly and the body assembly and by securing a binding material tothe body assembly and the lid assembly. The insulating layer can floatbetween the lower outer shell and the lower inner liner portion. Thebinding material can be formed of nylon, and the binding material can bestitched to the body assembly and the lid assembly. The lid assembly mayalso be welded to the body assembly. Additionally, the lid assembly maybe formed with a handle and a reinforcement layer that is more rigidthan the inner liner, the insulating layer, and the outer shell. Thelower inner liner portion in certain examples can be formed by injectionmolding.

The lower inner liner portion can be secured to the lower outer shell bya weld. The weld can be formed by clamping the lower outer shell to thelower inner liner portion with a top U-shaped portion, a plate portion,and a bottom U-shaped portion and applying a current through the topU-shaped portion, the plate portion, and the bottom U-shaped portion.The current can be applied through the top U-shaped portion, the plateportion, and the bottom U-shaped portion in a first direction to weld afirst side and the current can be applied in a second direction to welda second side.

The present invention is disclosed above and in the accompanyingdrawings with reference to a variety of examples. The purpose served bythe disclosure, however, is to provide examples of the various featuresand concepts related to the invention, not to limit the scope of theinvention. One skilled in the relevant art will recognize that numerousvariations and modifications may be made to the examples described abovewithout departing from the scope of the present invention.

What is claimed is:
 1. A insulating device comprising: an outer shelldefining a first sidewall; an inner liner forming a storage compartment;an insulating layer positioned in between the outer shell and the innerliner, the insulating layer providing insulation for the storagecompartment; an opening configured to allow access to the storagecompartment; and a closure adapted to substantially seal the opening,the closure being substantially waterproof so as to resist liquid fromexiting the opening when the insulating device is in any orientation. 2.The insulating device of claim 1 wherein the outer shell furthercomprises a second sidewall and a third sidewall and wherein the openingextends through the first sidewall, the second sidewall, and the thirdsidewall.
 3. The insulating device of claim 1 wherein the insulatingdevice is in a shape of a cuboid.
 4. The insulating device of claim 1wherein the inner liner and the outer shell form a joint and wherein thejoint comprises a vent to gases.
 5. The insulating device of claim 1wherein the outer shell comprises one or more handles and wherein a ventis formed adjacent to a location of the one or more handles.
 6. Theinsulating device of claim 1 wherein the closure is substantiallywaterproof so as to resist liquid from exiting the opening when theinsulating device is filled completely with water and is dropped from adistance of six feet.
 7. The insulating device of claim 1 wherein theouter shell defines a bottom wall extending in a first plane and whereinthe inner liner is secured to the outer shell in a second planeextending perpendicular to the first plane.
 8. The insulating device ofclaim 1 wherein the inner liner is formed of a first piece and a secondpiece and wherein the first piece is joined to the second piece by wayof a weld to define a seam and wherein the seam is covered with a seamtape.
 9. The insulating device of claim 1 wherein the inner liner isformed by way of injection molding.
 10. The insulating device of claim 1wherein the closure is a zipper and is substantially waterproof andwherein the zipper comprises a pull, the pull being formed of a cloth,string, or rope.
 11. The insulating device of claim 1 wherein thetemperature of the insulating device when filled with ice ofapproximately 0.52 lbs. per quart capacity of the insulating deviceincreases from 0° F. to 10° F. in a duration of 0.5 hours to 1.5 hours.12. The insulating device of claim 1 wherein the temperature of theinsulating device when filled with ice of approximately 0.52 lbs. perquart capacity of the insulating device increases from 10° F. to 50° F.in a duration of 22 hours to 28 hours.
 13. The insulating device ofclaim 1 wherein the temperature of the insulating device when filledwith ice of approximately 0.52 lbs. per quart capacity of the insulatingdevice increases from 0° F. to 50° F. in a duration of 24 hours to 30hours.
 14. The insulating device of claim 1 further comprising a lidassembly and a body assembly.
 15. The insulating device of claim 14wherein the lid assembly and the body assembly together form the innerliner, the insulating layer, and the outer shell.
 16. The insulatingdevice of claim 14 wherein the lid assembly includes at least a portionof the insulation layer.
 17. The insulating device of claim 14 whereinthe lid assembly includes a handle and a reinforcement layer that ismore rigid than the inner liner, the insulating layer, and the outershell.
 18. The insulating device of claim 1 wherein the insulating layerfloats between the inner liner and the outer shell.
 19. The insulatingdevice of claim 1 wherein the insulating layer is attached to the innerliner or the outer shell.
 20. A method comprising: forming a bodyassembly by forming a lower outer shell, placing a lower insulatinglayer into the lower outer shell, and securing a lower inner linerportion to the lower outer shell; forming a lid assembly of an upperouter shell, an upper inner liner portion and an upper insulating layertherebetween; and joining the lid assembly to the body assembly bysecuring a closure between the lid assembly and the body assembly and bysecuring a binding material to the body assembly and the lid assembly.21. The method of claim 20 wherein the insulating layer floats betweenthe lower outer shell and the lower inner liner portion.
 22. The methodof claim 20 wherein the binding material is nylon.
 23. The method ofclaim 20 wherein the binding material is stitched to the body assemblyand the lid assembly.
 24. The method of claim 20 wherein the lidassembly is also welded to the body assembly.
 25. The method of claim 20wherein the lower inner liner portion is formed by injection molding.26. The method of claim 20 wherein the lower inner liner portion issecured to the lower outer shell by a weld.
 27. The method of claim 26wherein the weld is formed by clamping the lower outer shell to thelower inner liner portion with a top U-shaped portion, a plate portion,and a bottom U-shaped portion and applying a current through the topU-shaped portion, the plate portion, and the bottom U-shaped portion.28. The method of claim 27 wherein the current is applied through thetop U-shaped portion, the plate portion, and the bottom U-shaped portionin a first direction to weld a first side and the current is applied ina second direction to weld a second side.
 29. The method of claim 20further comprising forming the lid assembly with a handle and areinforcement layer that is more rigid than the inner liner, theinsulating layer, and the outer shell.
 30. The method of claim 20further comprising attaching the insulating layer to the inner liner orthe outer shell.